Revised USPS Hazmat Packaging Standards for Mail

Posted on 1/28/2025 by Lion Technology Inc.

New Rules for Hazmat Mailers Take Immediate Effect

Effective January 27, 2025, the US Postal Service has revised its standards for mailing hazmat/dangerous goods to require "rigid" outer packaging of a certain strength for most regulated materials. USPS announced the changes to Publication 52, Hazardous, Restricted, and Perishable Mail, in a Final Rule.

Other revisions in the Final Rule include:

Revising the requirements for mailing lithium batteries.
Removing quantity restrictions for nonregulated toxic materials like pesticides and insecticides, provided that the new packaging requirements are followed.
Removing the requirement to include a phone number on the lithium battery mark.

The Postal Service cites a concerning increase in hazmat mail incidents between 2020 and 2022 as a key influence for new, more stringent mailability rules. A boom in eCommerce shipping, USPS believes, led to more incidents involving hazardous materials released during transportation and/or removed from the mail system.

Changes made in 2023, USPS says, already helped lower the incident rate by 20%.

New Packaging Strength Requirement (All Hazmat)

Moving forward, mailers of hazardous materials must use rigid outer packaging that meets minimum strength requirements based on “edge crush” and “burst test” performance. USPS defines “rigid” to mean:

“Unable to bend or be forced out of shape, not flexible. Rigid outer packaging is generally interpreted to mean a fiberboard (cardboard) box or outer packaging of equivalent strength, durability, and rigidity.”

Revised USPS Hazmat Packaging Standards for Mail

Revised Rules for Lithium Batteries by Mail

For shippers of lithium batteries contained-in-equipment by mail, the rule allows the use of padded or poly bags as outer packaging, provided the equipment containing the batteries is placed in a secondary container (i.e., the original manufacturer’s box) that can withstand a 1.2-meter drop test.

Read the USPS Final Rule in the January 27, 2025 Federal Register.

Tags: hazmat, hazmat shipping, USPS

Find a Post

Search for:

Compliance Topics

Compliance Archives

Lion was very extensive. There was a lot of things that were covered that were actually pertaining to what I do and work with. Great Job. I will be coming back in three years!

Tony Petrik

Hazmat Shipping Professional

Very well structured, comprehensive, and comparable to live training seminars I've participated in previously. I will recommend the online course to other colleagues with training requirement needs.

Neil Luciano

EHS Manager

The instructor had knowledge of regulations and understanding of real-world situations. The presentation style was engaging and fostered a positive atmosphere for information sharing.

Linda Arlen

Safety & Environmental Compliance Officer

Lion's training was by far the best online RCRA training I've ever taken. It was challenging and the layout was great!

Paul Harbison

Hazardous Waste Professional

Lion courses are the standard to which all other workshops should strive for!

Brody Saleen

Registered Environmental Health Specialist

Lion does a great job summarizing and communicating complicated EH&S-related regulations.

Michele Irmen

Sr. Environmental Engineer

This was the 1st instructor that has made the topic actually enjoyable and easy to follow and understand. Far better than the "other" training providers our company has attended!

Lori Hardy

Process & Resource Administrator

The instructor was probably the best I ever had! He made the class enjoyable, was humorous at times, and very knowledgeable.

Mary Sue Michon

Environmental Administrator

The instructor was very engaging and helped less experienced people understand the concepts.

Steve Gall

Safety Leader

Excellent. I learned more in two days with Lion than at a 5-day program I took with another provider.

Francisco Gallardo

HES Technician

Download Our Latest Whitepaper

This report details major changes for hazardous waste generators from US EPA’s Generator Improvements Rule, as well as the latest updates from states that are still working to adopt new, stricter Federal requirements.

Download

By submitting your phone number, you agree to receive recurring marketing and training text messages. Consent to receive text messages is not required for any purchases. Text STOP at any time to cancel. Message and data rates may apply. View our Terms & Conditions and Privacy Policy.