What is ADR packaging? How to pack hazardous materials?

What is ADR packaging?

ADR packaging is the packaging for the carriage of dangerous goods. They must comply with certain standards that are designed to ensure safety during transport.

How should hazardous materials be packed?

Hazardous materials must be packed in packages of good quality and robust enough to withstand the hardships of transportation (such as shocks and loading operations). In addition, each consignment must be made and sealed in such a way as to prevent the hazardous contents from escaping to the outside.

This means that it should be able to withstand normal transport conditions, i.e. vibration, temperature and pressure variations, as well as humidity.

Equally important, the packaging should be sealed in accordance with its manufacturer's instructions. It must also not have any material residues on the outer walls (no matter whether it is new or secondary).

Last but not least, the packaging material must be resistant to the goods being transported. It must not react with it or be weakened or damaged by contact with the hazardous substance in question.

How should hazardous liquids be packaged?

Hazardous should be packed in such a way as to leave a free space in the package. This protects against loss of contents or deformation of the package as a result of an increase in the volume of the liquid under the influence of temperature.

The second point is the resistance of the packaging to the internal pressure that may occur during the transport of hazardous materials. If, on the other hand, there is a risk of pressure build-up due to gases emitted by the liquid, the package should be fitted with a venting device only if the gases do not pose a (fire/toxic) hazard. Vehicles transporting hazardous liquids should also be equipped with appropriate chemical hoses to safely transport the material.

What is the purpose of ADR packaging?

The purpose of ADR packaging is to ensure the safe carriage of dangerous goods by establishing specific packaging and labelling requirements.

What are the types of ADR packaging?

There are four basic types of ADR packaging:

• P - packages with a capacity of up to 450 litres or 400 kg net (e.g. crates, drums or canisters); 
• IBC - large bulk containers (abbreviated DPPL) with a capacity greater than 450 litres or 400 kg net (but a maximum of 3m3); 
• R - light metal packaging with a capacity of up to 40 litres or 50 kg net; 
• N - large packaging with a capacity greater than 450 litres or 400 kg net (but with a maximum of 3m3).

In addition to this, individual packaging is also divided into types and the materials from which they are made. In terms of types, we distinguish between:

• Drum (1), 
• Canister (3), 
• Box (4), 
• Bag (5), 
• Composite packaging (6), 
• Light metal packaging (0).

The numbers in brackets serve as a code for certification.

Which materials are used to build ADR packaging?

As for the available materials for ADR packaging, we distinguish:

• Steel (A), 
• Aluminium (B), 
• Wood (C), 
• Plywood (D), 
• Wood-based material (F), 
• Cardboard (G), 
• Plastic (H), 
• Fabric (L), 
• Multiplex paper (M), 
• Metal other than steel or aluminium (N), 
• Glass, porcelain or stoneware (P).

The letters in brackets serve as a code for certification.

How to choose ADR packaging?

In order to choose the right ADR packaging, you need to pay attention to the material it’s constructed from, the capacity, structural integrity and certification markings.

Material

The packaging material must be resistant to the hazardous substance being transported. Above all, it must not react dangerously with it. Furthermore, the substance should not cause degradation of the packaging material.

Capacity

Capacity is another important issue, as the ADR agreement regulates the permissible quantity of individual dangerous goods that can be contained in a single package. Furthermore, the volume of the package itself is also limited to a maximum of 3m3.

Structural integrity

Structural integrity is one of the requirements that must be met for a package to be compliant.

This is because the integrity of the package minimises the risk of damage, which also translates into a lower likelihood of leakage or spillage of the contents. As a result, the safety of the goods being transported is significantly increased.

Certification markings

Any packaging for the transport of hazardous materials must be certified.

In the UK, this is handled by the Secretary of State for Transport. However, not directly. The Dangerous Goods Office (DGO) operates the UN packaging certification scheme under the performance testing, certification, and labelling arrangements on behalf of the Secretary of State.

Therefore, when you choose an ADR package, make sure it has a certification mark. This is also proof that the type of package meets all the necessary requirements.

What does a certification label consist of?

The certification label consists of the following elements:

• UN symbol - confirms that the package meets the guidelines. The alternative is: 
• Symbol "RID/ADR” - used for composite packaging (glass, porcelain or stoneware) and light metal packaging that complies with the simplified conditions. 
• Package code - identifies the type of package. It consists of:
• an Arabic numeral that indicates the type of packaging (e.g. drum, sack, crate); 
• a capital letter that refers to the construction material (e.g. plywood, plastic, multiplex paper); 
• an Arabic numeral that indicates the category of the packaging together with the type (e.g. with a removable lid, with dustproof walls, without liner and inner lining). 
• In addition, there may be letter symbols with additional meaning in the packaging code, e.g.: T (emergency packaging) or V (special packaging).
• Packaging group letter - indicates which materials the packaging can be used for. There are three letters:
• X - packaging for materials in Packing Groups I, II and III; 
• Y - packaging for materials in Packing Groups II and III; 
• Z - packaging for materials in Packing Group III. 
• Elements of labelling resulting from the physical state of the material and the type of packaging specified, e.g.: 
• for solid materials - maximum gross mass in kg for packaging or inner packaging; 
• for liquid materials - the relative density of the liquid. 
• The production date of the package, which depends on the type of package. We distinguish: 
• for packages - the last two digits of the year of manufacture; 
• for DPPL, large packs, as well as plastic reels and canisters, the month and year of production. 
• Symbol of the country authorising the affixing of the label. 
• Name of the certification body authorised by the competent authority. 
• Manufacturer's name or other identification mark. 
• Additional markings, e.g.: 
• load used in the pile resistance test (kg) for DPPL and large packages;
• tare (tare weight of the package in kg) - for DPPLs made of metal, rigid plastic, composite, cardboard and wood; 
• manufacturer's serial number - for metallic DPPLs.

Example of UN certification code from the UK:

How should ADR packages be marked?

ADR packages should be marked following the ADR designations. The proper marking includes:

• Marking for testing, construction and approval of packaging, as well as large packaging, DPPLs and pressure vessels. 
• UN numbers concerning the dangerous goods contained in the package (preceded by the letters "UN"). 
• Warning labels showing potential hazards. The labels should be placed on the same side of the package, close to the other labels, if more than one label is required. In addition: 
• For Class 1 (Explosive substances and articles), Class 2 (Gases), and Class 7 (Radioactive materials) goods, should be affixed close to the correct shipping name of the dangerous good. 
• The label must be visible and it must be ensured that it is not covered by other markings. It is permissible to affix the warning sticker on a well-fixed tag or in some other appropriate manner if the small size or irregular shape of the package does not allow for proper affixing of the label .
• Proper shipping name of dangerous goods - The requirement applies to dangerous goods of Class 1 (Explosive substances and articles), Class 2 (Gases), and Class 7 (Radioactive materials). In addition: 
• If carriage is performed on the territory of Poland, it is sufficient to provide a proper shipping name only in Polish. 
• In case of international carriage, a proper shipping name in one of the following languages is also required: English, German, or French.
• Directional arrows - Valid for combination packs containing liquid material, individual packs fitted with venting devices, and cryogenic vessels intended for the carriage of liquefied chilled gas. In addition:
• The marking should be placed on two opposite sides of the package. Arrows indicate how the item is to be loaded into the vehicle. 
• Label for environmentally hazardous materials if this is what is being transported.

Can ADR packaging be reused?

ADR packaging can be reused, but it must meet the same requirements as if it were new. This is primarily a question of adequate strength to cope with the conditions encountered during transport, such as loading and shocks.

In addition, the packaging should be checked before each re-use. Also, it must not contain residues of incompatible hazardous materials and its structural integrity must remain intact.

This means that you cannot use a fibreboard box with a tear or a barrel with a deep gouge on the surface. Metal and plastic drums and containers must also meet minimum wall thickness requirements and, in most cases, also pass a leak test.

Who is responsible for ensuring compliance with the ADR?

It is the responsibility of all those involved in the carriage to ensure ADR compliance: the shipper, the carrier, the consignee, and also the unloader.

How often should ADR packaging be checked?

The frequency of ADR packaging inspections depends on the type of packaging and the regulations that apply to it. Some types of packaging require periodic inspections every two years, while others may require testing after a certain period from the date of manufacture. It is important to consult the relevant regulations and guidelines to determine the specific requirements for a particular type of packaging.

Summary

Choosing the right ADR packaging for the hazardous material being transported is essential to ensure compliance with regulations and an adequate level of protection during transport. This is why knowing the requirements for the shipment is so important.

The right packaging is of such good quality that it will withstand the rigours of transport. Furthermore, it is resistant to the transported substance and does not react with it in a hazardous manner.

Appropriate labelling is also very important. Above all, the packaging should be certified. In addition, the shipper must label it with the necessary stickers that are appropriate to the goods being transported.