ASTM D4919-23

This document is not an ASTM standard and is intended only to provide the user of an ASTM standard an indication of what changes have been made to the previous version. Because
it may not be technically possible to adequately depict all changes accurately, ASTM recommends that users consult prior editions as appropriate. In all cases only the current version
of the standard as published by ASTM is to be considered the official document.
Designation: D4919 − 17 D4919 − 23
Standard Guide for
Testing of Hazardous Materials (Dangerous Goods)
Packagings
This standard is issued under the fixed designation D4919; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
This standard has been approved for use by agencies of the U.S. Department of Defense.
1. Scope*
1.1 The main focus of this guide is to identify This guide identifies the key information required for United Nations (UN)
packaging certification to ensure the selected packaging will be certified to the appropriate level for its intended use. This document
also use and provides guidance for locating relevant sections of the United States Department of Transportation Title 49 Code of
Federal Regulations (CFR). Consult with a regulatory specialist whenever needed.
1.2 This guide is intended to assist provides assistance in determining the appropriate performance tests required to certify
packaging designs to the United States Department of Transportation Title 49 Code of Federal Regulations performance oriented
packaging standards based on the United Nations Recommendations on the Transport of Dangerous Goods.
1.3 This guide covers the testing for transportation of hazardous materials (dangerous goods) packagings for net masses not
exceeding 400 kg (880 lb) or capacities not exceeding 450 L (119 gal), excepting packagings for infectious substances, radioactive
materials, cylinders and other receptacles for gases.
1.4 This guide does not replace domestic or international regulatory requirements for hazardous materials packaging but is
strongly recommended to be used in conjunction with those regulations.
1.5 The user of this guide must be trained in accordance with the United States Department of Transportation Title 49 Code of
Federal Regulations (49 CFR) as required by 172.700 and should be familiar with other applicable hazardous materials regulations
such as: International Civil Aviation Organization (ICAO) Technical Instructions for the Safe Transport of Dangerous Goods by
Air, and the International Maritime Dangerous Goods Code (IMDG Code) and carrier rules such as International Air Transport
Association (IATA) Dangerous Goods Regulations.
1.6 The values stated in inch-pound units are to be regarded as standard. The values given in parentheses are mathematical
conversions to SI units that are provided for information only and are not considered standard.
1.7 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility
of the user of this standard to establish appropriate safety and healthsafety, health, and environmental practices and determine
the applicability of regulatory requirementslimitations prior to use.
1.8 This international standard was developed in accordance with internationally recognized principles on standardization
established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued
by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
This guide is under the jurisdiction of ASTM Committee D10 on Packaging and is the direct responsibility of Subcommittee D10.22 on Hazardous Materials.
Current edition approved April 1, 2017March 15, 2023. Published June 2017April 2023. Originally approved in 1989. Last previous edition approved in 20082017 as
D4919 – 03D4919 – 17.(2008) which was withdrawn January 2017 and reinstated in April 2017. DOI: 10.1520/D4919-17. DOI: 10.1520/D4919-23.
*A Summary of Changes section appears at the end of this standard
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
D4919 − 23
2. Referenced Documents
2.1 ASTM Standards:
D323 Test Method for Vapor Pressure of Petroleum Products (Reid Method)
D642 Test Method for Determining Compressive Resistance of Shipping Containers, Components, and Unit Loads
D685 Practice for Conditioning Paper and Paper Products for Testing
D996 Terminology of Packaging and Distribution Environments
D999 Test Methods for Vibration Testing of Shipping Containers
D4169 Practice for Performance Testing of Shipping Containers and Systems
D4332 Practice for Conditioning Containers, Packages, or Packaging Components for Testing
D4359 Test Method for Determining Whether a Material Is a Liquid or a Solid
D4577 Test Method for Compression Resistance of a Container Under Constant Load
D4991 Test Method for Leakage Testing of Empty Rigid Containers by Vacuum Method
D5276 Test Method for Drop Test of Loaded Containers by Free Fall
D5570 Test Method for Water Resistance of Tape and Adhesives Used as Box Closure
D7660 Guide for Conducting Internal Pressure Tests on United Nations (UN) Packagings
D7790 Guide for Preparation of Plastic Packagings Containing Liquids for United Nations (UN) Drop Testing
D7887 Guide for Selection of Substitute, Non-hazardous, Liquid Filling Substances for Packagings Subjected to the United
Nations Performance Tests
D8135 Guide for Selection of Substitute, Non-hazardous, Particulate Solid Filling Substances for Packagings Subjected to the
United Nations Performance Tests
D8409 Guide for Conducting Stacking Tests on UN Packagings Using Guided or Unguided Loads
2.2 ISO Standard:
ISO 535 Determination of Water Absorption of Paper and Board (Cobb Method)
2.3 United Nations Document:
United Nations Recommendations on the Transport of Dangerous GoodsGoods, Model Regulations (UN Orange Book)
2.4 Regulatory Documents:
International Air Transport Association (IATA) Dangerous Goods Regulations
International Civil Aviation Organization (ICAO) Technical Instructions for the Safe Transport of Dangerous Goods by Air
International Maritime Dangerous Goods Code (IMDG Code)
49 CFR United States Department of Transportation Code of Federal Regulations Title 49, Transportation, Parts 100-199
2.5 Industry Document:
Industrial Steel Drum Institute (ISDI) and Reusable Industrial Packaging Association (RIPA) Hazardous Materials Packaging
Testing Procedures for Steel Drums
3. Terminology
3.1 Reference 49 CFR, Section 171.8: Definitions and Abbreviations.
3.2 Reference 49 CFR, Part 173, Subpart D: Definitions Classification, Packing Group Assignment and Exceptions for Hazardous
Materials other than Class 1 and Class 7 (for example, definition of flammable liquid).
3.3 Reference 49 CFR, Sections 178.503-178.523 for Non-bulk packaging standards (for example, 1A1, 1H2, 4G, etc.).
3.4 Reference 49 CFR, Section 178.601(c): General Requirements, Definitions.
For referenced ASTM standards, visit the ASTM website, www.astm.org, or contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM Standards
volume information, refer to the standard’s Document Summary page on the ASTM website.
Available from American National Standards Institute (ANSI), 25 W. 43rd St., 4th Floor, New York, NY 10036, http://www.ansi.org.International Organization for
Standardization (ISO), ISO Central Secretariat, Chemin de Blandonnet 8, CP 401, 1214 Vernier, Geneva, Switzerland, https://www.iso.org.
Available from the UN Economic Commission for Europe, Information Service, Palais des Nations, CH-1211 Geneva 10, Switzerland, http://www.unece.org/trans/
danger/danger.htm.
Available from International Air Transport Association (IATA), 800 Place Victoria, P.O. Box 113, Montreal, Quebec H4Z 1M1, Canada, http://www.iata.org.
Available from International Civil Aviation Organization (ICAO), 999 University St., Montreal, Quebec, H3C H57, Canada, http://www.icao.int.http://www.icao.org.
Available from International Marine Organization, 4 Albert Embankment, London, Ontario 5E1 7SR, Canada, SE1 7SR UK, http://www.imo.org.
Available from Superintendent of Documents, U.S. Government Printing Office, Washington, DC 20402-9371 (website: hazmat.dot.gov).(www.phmsa.dot.gov/phmsa-
regulations).
Available from the Industrial Steel Drum Institute (ISDI), P.O. Box 790, Severna Park, MN 21146-0790. www.whysteeldrums.org; and Reusable Industrial Packaging
Association (RIPA), 51 Monroe Street Suite 812, Rockville, MD 20850, Tel. 301.577.3786, www.reusablepackaging.org
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3.5 The terms hazardous materials and dangerous goods are considered synonymous.
3.6 Reference Terminology D996.
3.7 Other terms may be found in modal specific regulatory documents listed in 2.4.
3.8 Definitions of Terms Specific to This Standard:
3.8.1 Packing Group—Hazardous Materials are assigned to a Packing Group based on the degree of danger as follows:
3.8.1.1 Packing Group I—Substances presenting great danger.
3.8.1.2 Packing Group II—Substances presenting medium danger.
3.8.1.3 Packing Group III—Substances presenting minor danger.
3.8.2 Performance Standard—UN certified Packagings are authorized to transport hazardous materials and are marked to a
performance standard as follows:
3.8.2.1 Performance Standard “X” Packaging—May be used to transport hazardous materials in Packing Groups I, II, and III.
3.8.2.2 Performance Standard “Y” Packaging—May be used to transport hazardous materials in Packing Groups II and III.
3.8.2.3 Performance Standard “Z” Packaging—May only be used to transport hazardous materials in Packing Group III.
4. Significance and Use
4.1 The UN performance tests are based on the degree of hazard presented by the proposed hazardous material(s) to be packaged.
4.2 Substances and articles which are hazardous are assigned to a specific packing group as defined in 3.8.1 and may be
determined by referencing 49 CFR 172.101 hazardous materials table.
4.3 Only packaging designs that have been successfully tested to the UN performance standards as defined in 3.8.2 may be marked
with a UN mark. have the UN specification mark applied to the outer packaging. Hazardous Materials may not be transported in
a packaging that does not bear the appropriate UN specification markings unless otherwise authorized by the applicable competent
authority.
4.4 Packages successfully tested to the UN performance standards may or may not withstand the North American distribution
environment. To further evaluate the suitability of the package it is strongly recommended that additional tests as detailed in
Practice D4169 or other carrier specified test requirements be conducted.
5. Procedure
5.1 Introduction—Hazardous materials must be offered for transportation within the United States in packagings authorized by
U.S. DOT 49 CFR. When UN specification packaging is required for shipping hazardous materials, this packaging must first be
subjected to and meet the UN performance standards as outlined in 49 CFR. It is recommended the user of this document review
key areas of 49 CFR to gain a better understanding of the domestic requirements for package certification. The following are
suggested areas to review:
5.1.1 49 CFR, 173.24, and 173.24a General Requirements for Packagings and Packages—This section of the regulations contains
information on the following: General applicability requirements, Packagings manufactured outside the U.S., Compatibility,
Venting of Packagings, Filling Requirements, Vibration Requirements, Filling Limits, Vapor Pressure Determinations and other
issues.
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5.1.2 49 CFR, 173.27 General Requirements for Transportation by Aircraft—This section of the regulations contains information
on the following: Pressure capability requirements for packagings transporting liquids, Closure requirements, and requirements for
the use of Absorbent Materials.
5.1.3 49 CFR, 178.601 General Requirements—This section of the regulations contains information on the following: Design
Qualification, Periodic Retesting, Production Testing, and Selective Testing for UN packagings.
5.1.4 49 CFR, 178.602 Preparation of Packagings and Packages for Testing—This section of the regulations contains information
on filling requirements for liquids and solids packaging certification along with conditioning requirements.
5.1.4.1 When selecting liquid fill materials for package testing the user of this guide should consult Guide D7887 for guidance
on the selection of the proper liquid fill material for the test specimens.
5.1.4.2 When selecting solids fill materials for package testing the user of this guide should consult Guide D8135 for guidance
on the selection of the proper solids fill material for the test specimens.
5.1.4.3 When preparing packages for testing the user of this guide should consult Practice D4332 and Guide D7790 for guidance
on package conditioning prior to testing.
5.2 Use of UN Certified Packaging— A UN packaging may be used for different products under the same certification provided
the hazardous material and packaging are compatible, the regulations authorize the use of the packaging for the intended hazardous
material, and the UN packaging certification is appropriate for the intended product.
5.3 Key Information for Packaging Certification—To ensure the selected packaging will be certified to the appropriate level for
its intended use the information outlined in 5.3.1 – 5.3.4 should be obtained and carefully reviewed.
5.3.1 Packaging Standard—Determine if the packaging configuration meets the construction and specification requirements of one
of the UN standards (for example, Fiberboard Box, Metal Drum, Plastic Drum, etc.) listed in 49 CFR, 178.504–178.523. If the
packaging selected does not meet these requirements, approval may be required from the competent authority for UN certification
(49 CFR, 178.601(h)).
5.3.2 Hazardous Material Information—Determine what products are to be shipped in the selected packaging. Consideration
should be given to new or potential products to be shipped. The type of hazardous materials being shipped will determine the
appropriate performance tests.
5.3.2.1 Packing Group—Packagings must be selected based on the hazards presented in transportation according to the respective
Packing Group assignments of the intended hazardous materials as defined in 3.8.1.
NOTE 1—If different products are intended to be shipped in the selected packaging, keep in mind the product presenting the greatest danger may not be
the product resulting in the highest specific gravity or heaviest gross mass (for example, a Packing Group I liquid may have a specific gravity of 1.1, and
a Packing Group II liquid may have a specific gravity of 1.9). This information is important for determining the appropriate performance tests. The
following sections of 49 CFR pertaining to “non-bulk filling limits” provides guidance for the use of UN certified packagings: 49 CFR, 173.24a(b)(1),
173.24a(b)(2), and 173.24a(b)(3). Note, these sections only apply to single and composite packagings and not combination packagings.
5.3.2.2 Hazardous Material Type (Liquid or Solid)—Determine if the selected packaging will be used for shipping liquid or solid
hazardous materials or both (see Test Method D4359 for determining whether a material is a liquid or solid). The UN test
requirements are different for solids and liquids. If the packaging is intended for shipping both liquids and solids, two separate
certification tests may need to be performed. Single and composite packagings tested for liquids may be authorized for solid
materials (see 49 CFR 173.24a(b)(3)). Combination packagings require separate testing for liquids and solids. Consult the most
recent revision of the hazardous materials regulations to determine certification requirements.
5.3.2.3 Specific Gravity for Liquids—Using product Material Safety Data Sheets (MSDS) or other acceptable methods, obtain
information on the maximum specific gravity of the liquid product(s) to be shipped in the selected packaging. Testing should be
conducted based on the highest specific gravity product for single and composite packagings and the highest specific gravity
product resulting in the heaviest gross mass for combination packagings. This information is needed to determine test levels and
authorized gross mass of the packaging.
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5.3.2.4 Gross Mass for Solids—Using product MSDS or other acceptable methods, obtain information on the maximum gross
mass (based on net fill weight) of the solid product(s) to be shipped in the selected packaging. This information is needed to
determine test fill weights and authorized gross mass of the packaging.
5.3.2.5 Vapor Pressure of Liquid Material—For liquid hazardous materials, information on the vapor pressure of the material
determined at 50 or 55°C50 °C or 55 °C should be obtained using the appropriate ASTM Standard (see Test Method D323) or other
acceptable methods (see 49 CFR, 173.24a(b)(4)). For single and composite packaging this information is required to determine the
appropriate hydrostatic test pressure. For inner packagings of a combination packaging intended for shipping liquids by air
transportation, this information is required to determine the appropriate pressure differential test requirements.
5.3.3 Mode of Transportation—Determine the intended mode(s) of transportation for the selected packaging. Certain modes of
transportation may require additional testing or testing to a more stringent level. (for example, the inner packagings of a
combination packaging intended to contain liquids and shipped by air transportation must be capable of passing a pressure
differential test (see 49 CFR, 173.27(c)). This capability requirement does not apply if the same package is shipped by surface
transportation only.)
5.3.4 Packaging Assembly Functions—Determine how the packaging will be assembled. Information should include:
5.3.4.1 Package Description,
5.3.4.2 Special closure functions,
5.3.4.3 Closure application torque,
5.3.4.4 Box sealing method (taped, stitched, glued),
5.3.4.5 Inner packaging orientation,
5.3.4.6 Cushioning requirements and orientation, and
5.3.4.7 Any other requirements to assemble the package as for shipment.
NOTE 2—The form in Table 1 may be used to document key information required for the conduct of the UN certification test.
6. Test Overview
6.1 Design Qualification testing procedures are intended, as explicitly stated in the HMR, to be the minimum performance
capability levels for packaging manufactured to transport Hazardous Materials under conditions normally incident to transporta-
tion. [See: 49 CFR §178.601(a)]. The HMR tests are designed to be gross package capability evaluations that can be performed
in a similar manner in all parts of the world, but under circumstances with some variance in test facility capabilities. This is an
intentional feature of the test designs and protocols. The focus of HMR testing is not the determination of quantifiable, comparison
data to allow for analytical evaluation. In package testing, “Conditioning” of the packages or packaging materials prior to testing
is known to affect accuracy, repeatability and precision of results over sample sets. The conditioning requirements of the testing
procedures in the HMR are not reflective of what is understood as best practices for determining analytical test results. It is
recommended that facilities performing the HMR tests consult the guidance on conditioning in the relevant ASTM documents for
any particular packaging material as applicable. The following standards are commonly used for conditioning: Practice D4332 and
Practice D685.
6.2 Tables 2-5 provide an overview of the required tests based on the hazardous material (liquid or solid) and the packaging type.
The tables include the reference sections within this document that provide more detailed information for each UN test and the
corresponding 49 CFR reference. The definition of the packaging type is also included at the top of each table.
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TABLE 1 Design Qualification Packaging/Test Parameters—Key Information
Package Description
(general information should include; size, shape,
material of construction or spec numbers or part
numbers to identify packaging and components)
UN Marking:
Record UN marking on previously certified packagings
Packaging Standard / UN ID Code
(5.3.1)
Packing Group
I II III
(5.3.2.1)
Packing Group
I (x) II (Y) III (Z)
(5.3.2.1)
Hazardous Material Type
Liquid Solid
(5.3.2.2)
Liquid—Specific Gravity
(5.3.2.3)
Solid—Gross Mass
(5.3.2.4)
Vapor Pressure of Liquid at 50 or 55°C
50°C (122°F) 55°C (131°F)
(5.3.2.5)
Vapor Pressure of Liquid at 50 °C or 55 °C
50 °C (122 °F) 55 °C (131 °F)
(5.3.2.5)
Mode(s) of Transportation
Air Ground Maritime
(5.3.3)
Packaging Assembly Functions Special Closure Functions (for example, Bolt Ring, Lever Lock, Induction Seal, etc.):
(5.3.4)
(refer to closing instructions Packaging Assembly Functions (5.3.4)
Closure Application Torque(s):
supplied by the manufacturer (refer to closing instructions
or certifier for previously supplied by the manufacturer
A
Box Sealing Method:
certified packagings) or certifier for previously
certified packaging)
Inner Packaging Orientation:
Special Closure Functions (for example, Bolt Ring, Lever Lock, Induction Seal, etc.):
Cushioning Requirements:
Miscellaneous Requirements:
A
Tape used for sealing packages should meet water resistant requirements of Test Method D5570 [See: 49 CFR 178.516(b)(4)].
7. Drop Test
7.1 The drop test is typically one of the more difficult parts of the UN certification process and it is recommended the drop test
be conducted first. The user of this guide should review 49 CFR 178.603 for specific test information such as drop orientations
and pass/fail criteria. Drop tests are required for all types of packagings and should be conducted in accordance with Test Method
D5276.
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TABLE 2 Test Overview—Combination Packaging (reference Section 6)
NOTE 1—“X” indicates to conduct the test.
Definition: Combination packagings are a combination of packagings for transport purposes, consisting of one or more inner packagings secured in an
outer packaging.
Section in Required
UN Tests 49 CFR Liquids Solids
Document Samples
5 for Boxes
A,B
Drop 178.603 7 X X
6 for Drums
Leakproofness 178.604 8
Hydrostatic
178.605 9
Pressure
Stacking 178.606 10 X X 3
A,C
Vibration 178.608 11 X X 3
X 3
Pressure
173.27(c) 12 (Air Transport (Inner Packaging
Differential
Only) for Liquid)
X X 5
Cobb Water Combination Packaging
178.516 13 (4G Fiberboard (4G Fiberboard (outer fiberboard
Absorption Example
Box) Box) material samples)
A
Testing must be conducted on the complete package assembled as for shipment except for the Pressure Differential and Cobb Water Absorption Tests.
B
Drop test samples and orientations are determined by the shape (type) of outer packaging.
C
The vibration test is a capability requirement and not a “required” test. See 11.2.
TABLE 3 Test Overview—Bag (reference Section 6)
NOTE 1—“X” indicates to conduct the test.
Definition: Bags are flexible packagings made of paper, plastics film, textiles, woven material or other suitable materials.
Section in Required
UN Tests 49 CFR Solids
Document Samples
A
Drop 178.603 7 X 3
Leakproofness 178.604 8
Hydrostatic
178.605 9
Pressure
Stacking 178.606 10
B A
Vibration 178.608 11 X 3
Pressure
...