5 Common Mistakes Businesses Make When Shipping Hazardous Goods (And How to Avoid Them)

Shipping dangerous goods isn’t just about ticking boxes—it’s about protecting people, property, and the planet. Yet despite strict regulations and growing awareness, many businesses still fall into the same costly traps.

In this post, we explore five common mistakes made when handling dangerous goods and share real-world examples and stats to highlight why compliance is critical.

1. Incorrect or Missing Classification

The Mistake:

Failing to correctly classify a product under the relevant UN number and hazard class.

Case in Point:

A UK-based electronics retailer was fined after lithium batteries were incorrectly classified and shipped without appropriate markings. The consignment was seized at Heathrow, and the business faced delays, penalties, and damage to its carrier relationship.

Why It Happens:

Lack of internal expertise, assuming product safety, or copying old documentation from previous shipments.

Avoid It:

Always verify classification with up-to-date Safety Data Sheets (SDS), consult a DGSA, and keep current with regulation changes under ADR, IATA or IMDG codes.

2. Inadequate Packaging and Labelling

The Mistake:

Using non-compliant packaging or failing to apply the correct hazard labels and markings.

Stat:

According to the UK Civil Aviation Authority, 23% of rejected air freight shipments in 2023 involved inadequate or damaged packaging of dangerous goods.

Real-World Example:

A pharmaceutical distributor shipped Class 6.1 toxic substances in basic plastic containers, which leaked during transit. The carrier refused to continue shipment, and the incident triggered an internal HSE investigation.

Avoid It:

Use UN-certified packaging, follow the packing instructions for the specific UN number, and ensure all labels (including orientation arrows and limited quantity marks) are correct, visible, and durable.

3. Missing or Incomplete Documentation

The Mistake:

Dangerous goods declaration forms, transport documents, or packing certificates are missing, incomplete, or inaccurate.

Why It’s a Problem:

Incorrect paperwork is a red flag for enforcement bodies and often leads to shipment rejection or costly re-routing.

Case Study:

A cosmetics company shipping flammable aerosols by sea failed to include the proper Multimodal Dangerous Goods Form (MDGF). The shipment was delayed in port for 5 days, incurring demurrage charges of over £4,000.

Avoid It:

Check which documents are required by mode of transport. Double-check they are signed, consistent with labeling, and in line with the mode-specific rules (ADR, IMDG, IATA).

4. Relying on Carriers Without Internal Checks

The Mistake:

Assuming that the freight forwarder or courier will handle all dangerous goods compliance.

Reality Check:

The consignor (you) is ultimately responsible for ensuring goods are correctly classified, packaged, and documented.

Example:

An SME exporting cleaning chemicals to Germany assumed the carrier would "sort out the DG stuff." The shipment was refused at the port due to missing hazard labels, and the company lost its customer due to reputational damage.

Avoid It:

Have a trained member of staff responsible for DG compliance—or appoint a qualified external DGSA to advise or audit your procedures.

5. Lack of Training or Outdated Knowledge

The Mistake:

Staff handling dangerous goods have not been trained or received refresher training within the legally required timeframes (typically every 2 years for air, every 2–3 years for road/sea).

Stat:

A Dangerous Goods Academy survey of 78 UK-based exporters showed 41% had not updated their staff training in over 3 years, leaving them exposed to non-compliance.

Consequences:Incorrect declarations, mishandling, and safety risks—often without the business even realising until enforcement action is taken.

Avoid It:

Ensure all staff involved in packing, shipping, handling or documentation are trained in line with their responsibilities—and refresh training as regulations evolve.

✅ Key Takeaways for Your Business

• You’re legally responsible for DG compliance—even if you outsource shipping.

• Small mistakes in packaging, documentation or labelling can result in fines, delays, or revoked contracts.

• Regular training and internal reviews are essential to stay compliant.

• A qualified Dangerous Goods Safety Adviser (DGSA) can help protect your business from these risks.

🧭 Need Help Staying Compliant?

At Dangerous Goods Academy, we offer:

• CAA-approved training (Air, ADR, IMDG)

• DGSA qualification courses

• Membership Support for ongoing advice, templates, and guidance

👉 Explore our training programmes