PKG 491 - Hazardous Materials Packaging

Prerequisite: PKG 322 and PKG 323 or equivalent

Course Description: Review of current regulations, US, international, governmental and trade associations. Emphasis on USDOT regulations in Title 49, Code of Federal Regulations (49 CFR). Using the regulation to determine available protective packaging options. Specification of package labeling, marking and required laboratory testing. Principals of design for hazardous materials packaging. Training requirements for hazardous materials employees.

Evaluation: Three multiple choice examinations totaling 70%
One written case study project totaling 30%

Text: All required materials are available online in public domain.

Course Outline

Preliminaries and Administration
About MSU's Virtual University
Getting support and help. Getting your questions answered.
Course Materials: 49 CFR, other materials
Expectations for students, faculty
Evaluation

What is Hazardous Material (Dangerous Goods) ?
Organization of Code of Federal Regulations (CFR)
Relationship of USDOT and other regulators
Definition of Hazardous Materials: ref § 171.8
designated and criteria
HazMat, Dangerous Goods
Why regulate HazMat ?
Brief history: material/construction to performance oriented
example of each
How can we identify a HazMat ?
Material Safety Data Sheet, Table, meeting criteria
examples of each
Responsibility for identifying HazMat

The Regulators and Regulations
Process Outline: design, test, certify, produce, pack, ship
Types of regulators
governmental/state membership: (USDOT, ICAO)
trade association: (IATA)
Alphabet Soup
Dangerous Goods Regulations (DGRs): show documents
49 CFR (HM-181)
UN, IATA, ICAO, IMO
How students may get access to 49 CFR via internet
Enforcement: DOT role, fines

Responsibilities of parties
Who is the manufacturer of HazMat packaging?
Shipper, Manufacturer, Customer
ref § 178.2

Packaging for Hazardous Materials
Identification Codes: ref § 178.502
Types of packaging: 1, 2, 3...
Material of construction: A, B, C,
Category within type: 1, 2...
Composites
how different from combinations
Combinations
how different from composites
Bulk/non-bulk,
Intermediate Bulk Containers
Standards (§ 178.700-710
Inner packaging, primary, dunnage, closure
Examples
Special emphasis: 4G combinations

Hazardous Materials Identification and Classification
Responsibility and applicability: ref § 172.3
Proper Shipping Name (PSN): ref § 172.101 (hazardous material table)
descriptions, alternate spelling, symbols
Hazard Class or Division: ref § 172.101(d)
Forbidden designation
UN Numbers: ref § 172.101(e)
NA designation numbers
Packaging Group: ref § 172.101(f)
Practice with Hazardous Materials Table
Cross-referencing
Examples

From Table to Package
About the Table (§ 172.101)
Hazard Warning Label requirement: ref § 172.101(g); § 172.4XX
Special Provisions:
Packaging authorizations: Columns 8A, 8B, 8C ref § 172.101(i)
also general requirements: ref § 173.24
Exemptions
Non-bulk
Bulk, intermediate bulk
Quantity limitations: ref § 172.101(j)
Examination of Part 173 authorizations
example: § 173.201 non-bulk liquids Pkg Grp I
Construction requirements: ref § 178.504-178.523
Examples: simple, typical, complex

Marking and Labeling: ref § 178.503; 172.4XX
UN mark
ID code
Test standard
Specific Gravity/Mass
Test Pressure/Solid
Year, State, Name
Other marks
Labels review
multiple labels, special labels, no labels required
Placarding: ref § 172.519-172.560
Intermediate Bulk Containers
Examples for practice
Marking quiz

Documentation for Shipping ref: Part 172, Subpart C
Description on shipping papers
Shipper's Certification

Performance Testing: ref: Subpart M - § 178.600-178.609 (Supported by video clips)
Test types:
design qualification, periodic retest, selective
Preparation for testing
filling, conditioning
Test descriptions:
primary/internal
leakproofness
hydrostatic
transport/container
Cobb
stacking
vibration
drop
other
Testing for Intermediate Bulk Containers (IBCs)
Testing for etiologic agents (§ 178.609)
Results interpretation: pass/fail system
Reporting and documentation

Special Cases
Limited Quantity
Consumer Commodity
Small Quantity
ORM-D
Other

Designing HazMat Packaging
Consider past packages, tests, history
Use of packaging forms and materials
Special design considerations for hazmat products: liquids, etc.
Table requirements, authorizations, limitations
Design to test hazard level
Dealing with common exceptions
Marking and labeling
Examples

Training ref: Part 172, Subpart H § 172.700-704
Responsibility
Requirements
General awareness
Function specific
Safety
Initial and recurrent
Relationship to OSHA or EPA
Record keeping