Shipping dangerous goods internationally is never a simple task. From lithium batteries and chemicals to flammable liquids, even a minor mistake can result in shipment rejection, substantial fines, or even legal liability. In reality, many shippers believe they are “almost compliant,” but international regulations do not allow guesswork.
In this article, we analyze eight real-world failure cases involving the shipping of dangerous goods. We outline the most common reasons for shipment rejection and share practical solutions to help you ship DG goods internationally with confidence.
Table of Contents:
- Case 1: Incorrect Dangerous Goods Classification
- Case 2: Expired or Incomplete Safety Data Sheet (SDS)
- Case 3: Incorrect Packaging for Hazardous Materials
- Case 4: Missing or Incorrect Dangerous Goods Labels and Marks
- Case 5: Shipper’s Declaration Errors
- Case 6: Working with an Unqualified Freight Forwarder
- Case 7: Ignoring Country-Specific Dangerous Goods Regulations
- Case 8: Last-Minute Booking Without DG Pre-Check
Case 1: Incorrect dangerous goods classification
Problem
The shipper declared the cargo as general goods instead of hazardous materials.What happened
A shipment of industrial adhesive was booked as normal cargo. During inspection, authorities identified flammable properties under IMDG Class 3. The shipment was immediately rejected, and the container was held at the port.
Loss & risk
- Port storage fees
- Re-booking costs
- Potential fines for misdeclaration
Solution
Always verify the UN number, hazard class, and packing group before booking to ensure accuracy of the DG cargo. When shipping hazardous materials, classification must comply with the correct regulations. Use IATA DGR for air freight, IMDG Code for sea freight, and 49 CFR for US-related shipments based on the transport mode and destination.
In short, never rely solely on product names. Always request a valid Safety Data Sheet (SDS) and have it reviewed by a certified dangerous goods specialist to ensure accurate classification and regulatory compliance.
Case 2: Expired or incomplete Safety Data Sheet
Problem
The buyer provided an expired or incomplete Safety Data Sheet.
What happened
A shipment of lithium batteries was submitted for air transport. However, the airline rejected the SDS because it was outdated and lacked critical transport information. As a result, the airline cancelled the booking before accepting the cargo.
Loss & risk
- Flight cancellation
- Warehouse delays
- Missed delivery deadlines
Solution
When shipping dangerous goods internationally, ensure the SDS:
- Is issued within the last 3–5 years
- Matches the exact product
- Includes transport and regulatory sections
Case 3: Incorrect packaging for hazardous materials
The mistake
Using standard cartons instead of UN-approved packaging.
The consequence
A shipment of corrosive chemicals leaked during the handling process. Port authorities stopped the shipment immediately due to safety concerns.
Loss & risk
- Cargo damage
- Environmental cleanup costs
How to avoid it
UN-certified packaging is mandatory, not optional. Packaging must match the packing instruction specified by the IMDG, IATA, or ADR.
Additionally, inner packaging, cushioning, and absorbent materials must fully meet dangerous goods shipping requirements.
Case 4: Missing or incorrect dangerous goods labels and marks
Problem
Labels appear faded or missing, incorrectly sized, or placed in the wrong positions on the package or container.
What happened
A container bound for Europe was refused at the terminal because hazard labels were faded and orientation arrows were missing.
Consequence
- Re-labeling fees at the port
- Shipment delays and missed sailings
- Increased inspection frequency on future shipments
Solution
Verify all hazard labels, marks, and orientation arrows before delivering the cargo to the port or airport. Ensure all labels:
- Match the correct hazard class
- Remain durable and clearly visible throughout transport
- Comply with regulatory size, color, and placement requirements
Case 5: Shipper's declaration errors
Problem
Incorrect information on the Dangerous Goods Declaration (DGD).
What happened
A shipper listed the wrong net quantity per package. The airline rejected the booking during document review.Loss & risk
- Flight space loss
- Re-documentation costs
- Delayed delivery
How to avoid it
The DGD must be:- Accurate
- Consistent with the SDS and packaging
- Signed by a trained and certified shipper
Case 6: Working with an unqualified freight forwarder
The mistake
Using a forwarder without a dangerous goods handling approval.
What happened
Carriers rejected the shipment, triggering emergency handling costs, shipment delays, and reputational damage.
Solution
Always partner with a freight forwarder experienced in shipping hazardous materials. A qualified provider should offer:
- DG-trained and certified staff
- Carrier and airline dangerous goods approvals
- Proven experience on international routes
At Airsupply (ASLG), we handle dangerous goods as a core service, not an afterthought. Our certified team ensures full regulatory compliance from classification to final delivery, helping shippers move hazardous cargo safely, efficiently, and without costly surprises.
Case 7: Ignoring country-specific regulations
Problem
Following IMDG only, while ignoring local laws (e.g., 49 CFR for the US).
The consequence
Customs holds, regulatory penalties, extended storage costs, and potential delivery failure or forced re-export.
How to avoid it
Shipping dangerous goods internationally requires compliance with:
- International regulations
- Local import laws
- Carrier-specific policies
Each destination has its own enforcement priorities.
Case 8: Last-minute booking without DG pre-check
Mistake
No pre-check before booking the space.
Consequences and risks
Missed sailings or flight cancellations, production disruptions, and significantly higher costs for urgent replacement shipments.
Solution
Plan dangerous goods shipments early. Complete a full DG pre-check, including documentation, packaging, and labeling, before booking space.
Final advice: Reduce risk before it becomes a cost
Most dangerous goods shipping failures occur before the cargo ever moves—during classification, documentation, packaging, or booking. Avoiding these risks requires more than experience; it demands preparation, regulatory knowledge, and strict compliance.
At ASLG, dangerous goods transportation is a specialized service, not an add-on. Our certified team supports shippers with end-to-end compliance, from DG classification and documentation to carrier approval and international delivery. This approach ensures the safe and efficient shipment of dangerous goods from China to global markets.
