When shipping dangerous goods by ground, water or air, it is imperative to know that hazardous material packaging has the utmost integrity. Packages with integrity can help reduce the likelihood of hazardous accidents This same type of packaging can also reduce the chance that shipments will be rejected by overseas customs for non-compliance. So packages have to be rigorously tested for compliance to regulations developed by the UN, US Department of Transportation and International Maritime and International Civil Aviation Organizations.
DDL has been testing packaging of hazardous materials since 1990. DDL engineers working in well-equipped test facilities deploy a series of dynamic and static Hazmat tests designed to determine if the package meets compliance standards. Compliance testing includes calibrated drop, shock and stacking, electro-hydraulic vibration, compression, dead-load weight, internal pressure, leak and variation.
DDL Hazmat tests are typically deployed over a seven-day period. Special handling testing, however, can be expedited to a three-day turn around. DDL documents the results of all Hazmat tests both photographically and in written form. A final test report includes certification information required for ground, air and water transportation of hazardous materials. This information helps clients meet the requirements of the following regulations:
UN Recommendations on the Transport of Dangerous Goods, Chapter 9 D.O.T. Title 49
International Civil Aviation Organization (ICAO) Technical Instructions
International Maritime Organization`s (IMO) International Maritime Dangerous Good Code (IMDG).
Example: A 4G-combination package requires eleven complete packages. The packages are prepared as they would be for normal shipping, except that the inner containers are filled a non-hazardous substance -- usually water. The packing group and product density of the actual filler determines performance levels used for testing. The following tests are performed on a 4G-combination package.
- Cobb Water Absorption Test is performed on the corrugated box in accordance with ISO 535 & 49 CFR §178.516. Samples are conditioned at ambient conditions (73ºF/50% RH) for 24 hours prior to testing, which consists of a 30-minute soak in water. Five samples are prepared for this test.
- Drop Test involves five packages being dropped from the required drop height. Each sample is dropped once, in five different orientations, for a total of five drops. Primary inner packages (i.e. bottles) made of plastic are conditioned to 0ºF for 24 hours prior to testing. All other inner package materials are conditioned at ambient conditions (73ºF/50% RH) for 24 hours prior to testing. Reference: UN §5.1.6.3 and 49 CFR §178.603.
- Stack Test is performed on three complete packages by loading each individual box with a weight equivalent to a 3-meter stack of identical boxes. This test may be performed with or without the primary inner packages (i.e. bottles). The test duration is 24 hours per sample. Samples are conditioned at ambient conditions (73ºF/50% RH) for 24 hours prior to testing. Reference: UN §5.1.6.6 and 49 CFR §178.606.
- Vibration Test is performed on three complete packages and requires the operator to determine the acceleration needed to cause the package to leave the surface of the test table. This is accomplished by increasing the frequency of the shaker until the package separates enough so that a 1/16-inch shim can slide between the package and the table surface. Once the test level is determined, the test duration is one hour. Samples are conditioned at ambient conditions (73ºF/50% RH) for 24 hours prior to testing. Reference: 49 CFR §178.608.
Optional Tests:
- Hydrostatic Pressure Test is performed on three primary inner packages (i.e. bottles) by pressurizing the bottles to the required pressure with water for a specified duration. This test is only required for inner packages that contain liquid and will be shipped by air. Testing is performed on three samples, including the closures. Reference: UN §5.1.6.5 and 49 CFR §178.605.
- ISTA Test is a drop test and vibration test performed on three complete package designs. A ten-drop sequence and loose load vibration test are performed. This test is only required if UPS will be used to ship your package design containing hazardous materials.
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