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

Best course instructor I've ever had. Funny, relatable, engaging; made it interesting and challenged us as the professionals we are.

Amanda Schwartz

Environmental Coordinator

I like Lion's workshops the best because they really dig into the information you need to have when you leave the workshop.

Tom Bush, Jr.

EHS Manager

This is a very informative training compared to others. It covers everything I expect to learn and even a lot of new things.

Quatama Jackson

Waste Management Professional

The instructor was very patient and engaging - willing to answer and help explain subject matter.

Misty Filipp

Material Control Superintendent

I tried other environmental training providers, but they were all sub-standard compared to Lion. I will not stray from Lion again!

Sara Sills

Environmental Specialist

Lion was very responsive to my initial questions and the website was user friendly.

Michael Britt

Supply Chain Director

The instructor was very knowledgeable and provided pertinent information above and beyond the questions that were asked.

Johnny Barton

Logistics Coordinator

I had a positive experience utilizing this educational program. It was very informative, convenient, and rewarding from a career perspective.

John Gratacos

Logistics Manager

The instructor was energetic and made learning fun compared to dry instructors from other training providers.

Andy D’Amato

International Trade Compliance Manager

I can't say enough how pleased I was with this course! Everything finally makes sense.

Kim Graham

Lab Manager

Download Our Latest Whitepaper

Get to know the top 5 changes to OSHA’s revised GHS Hazard Communication Standard at 29 CFR 1910.1200 and how the updates impacts employee safety at your facility.

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.