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ADR Training
Packages And Bulk
Packages and bulk covers the transportation of dangerous goods in anything other than tanks, and is highlighted on the ADR training certificate. Dangerous goods transported in packages become subject to regulations depending on the amount. Dangerous goods carried in bulk (which are loose and unpackaged) are subject to regulations in any amount.
Dangerous goods may be carried on the road as they are not fully subject to regulations, because they are either underneath the transport category thresholds, they are in limited quantities or excepted quantities.
The UN design packages that safely contain dangerous goods under normal transport conditions. These packagings have been tested by dropping, leaks, pressure and stacking to ensure standards of compliance. Liquid intermediate bulk containers (IBCs) are also vibration tested (for IBCs after 2011). UN packagings have the UN approval mark on them, followed by a packaging code.
Both of the above are examples of the codes you might find on packagings.
Limited Quantities
These are based on the amount of dangerous goods in a receptacle. It varies from one dangerous goods to another and is based on column 3.4 of Table A in Volume 1 of the ADR books, produced by the UN. For example,
UN1835 Tetramethyl-ammonium hydroxide solution 8, PGIII (E) according to the ADR book Volume 1 Table A has a Limited quantity limit of 5L. This means that the receptacle below can contain UN1835 without being in ADR regulations, provided if the substance is carried in combination packagings not exceeding 30kg in boxes or 20kg in shrink wrapped trays.
The limited quantity labels and placards are instantly recognisable. Placards with a Y in them are for air transport.
If a vehicle of maximum mass of at least 12T carries at least 8T of limited quantity dangerous goods, the vehicle requires marking with the LQ placard on the front and back of the vehicle. Optionally, orange plates can also be displayed. Freight containers containing LQs must have the LQ placard on all four sides. Under this level, no LQ placards are displayed.
Vehicles under LQ placards are in tunnel category E. These are used for retail items for example hauling goods for supermarkets.
Transport Categories
These are the amounts of dangerous goods that can be transported before being in full ADR regulations. The transport category is more restrictive for the more dangerous products, and has been determined by the UN in Table A, Volume 1 of the ADR books.
Transport Category
0 - any amount will be subject to regulations
1 - 20 kg or litres
2 - 333 kg or litres
3 - 1000 kg or litres
4 - no amount fully subject to regulations
Solids, liquified gases, refrigerated liquified gases and dissolved gases are measured in kg. Liquids and compressed gases are measured in litres. Multiple loads with different transport categories need to be converted to give an overall value. Using the following conversion table, a quick calculation is performed. If this value is over 1000, the load is in regulations.
Transport Category Multiplier
0 - in scope in any amount
1 x 50
2 x 3
3 x 1
4 - any amount isn't in full regulation
Example:
A load carrying 1 210L drum of TC2 is under the transport category amount to be in regulations. If a 210L drum of TC3 was added, we would need a calculation:
TC 2: 210 x 3 = 630 and TC 3: 210 x 1 = 210
Added together, 840 is under 1000 therefore not subject to regulations.
Excepted Quantities
These are very small amounts of dangerous goods and usually used for air transport. It unlikely LGV drivers will come across this otherwise.
The receptacles inside the box are held in place and cushioned with outer packaging that can absorb the contents in the case of breakage of a liquid dangerous good. The maximum number of packages per vehicle must not exceed 1000. The excepted quantity amount for a product is determined by the UN Table A in Volume 1 of the ADR books.
Packages shall be marked with the excepted quantities mark. The closure of each inner packaging should be securely held in place with wire, tape or other positive means. Screw threads should have a leak proof cap that is resistant to the material. The Transport documents state ‘dangerous goods in excepted quantities’.
If a dangerous goods load is not under regulations, it is still subject to certain conditions:
A 2kg fire extinguisher
Dangerous goods awareness training
Instrinsically safe torch
Supervision rules
Drivers or crew members may not open packages (some exemptions for UK)
If needed, temperature control
Prohibition on smoking
What is not required:
ADR card
Instructions in writing
Transport document (still required for ADR journeys though)
Normal ADR fire extinguisher quantity and weight
Vehicle approval certificate
Vehicle markings
loading or unloading in a public place
Intermediate Bulk Containers (IBCs)
Can be used to transport liquids and solids from 0.5 to 3 tonnes. There are several variances on the manufacture types. Liquid containing IBCs are usually a plastic or metal inner caged inside a metal frame. These have an outlet tap at the bottom which can be used to decant product or connected directly to pipework. IBCs are used for both solids and liquids.
IBCs used for solids are known as the big bag. Usually, a spout is fitted to the base of the bah to off load the contained materials. The signs denote whether IBCs (lor large packagings) may be stacked or not.
Steel drums
The 210 litre steel drum is the most common method of packaging. Initially from the USA oil industry, known as the 55 gallon barrel; used as a basis to cost crude oil. Derived from the wooden barrel in the 1900’s.
Can be used for both liquids and solids. Tops can be fully separated for solids or have a filling hole and bung for liquids.
Hoops are integrally manufactured into the structure of the drum to aid handling and add strength. Usually the steel is 1mm thick, however the manufacture is thicker depending on the danger of the goods contained. For corrosives, drums generally have a protective inner lining known as a composite drum.
Plastic Drums
Plastic drums are available in a wide range of shapes and sizes. They are usually lighter than steel drums and can resist most corrosive materials more effectively. They are however more expensive than steel drums so they tend to be used in applications where their advantages pays off. These have a 5 year life span.
Sacks
Usually used for solids between 20-25kg. For use with dangerous goods they are normally made form plastic. The thickness of the plastic may vary depending on the degree of the danger; some consignors prefer to use two or more sacks to improve the security of the contents.
Sacks are mostly loaded on to pallets in a brickwork fashion and overpacked. They offer little resistance from sharp objects.
Gas Cylinders
Very strong in design to withstand the high internal pressure. They can be made from up to 10mm high grade steel. The valve is the most vulnerable part of the cylinder. If the valve is sheared off the cylinder will rocket as hundreds of tonnes of pressure rapidly escapes from it. Gas cylinders must always be securely stowed during transport.
Combination Packages
Generally a fragile receptacle packed in a fibreboard box for protection. Must be protected from weather.
Drivers and loaders have a duty of care to load a vehicle safely and properly. In particular:
Never allow leaking packages on to your vehicle
Clean up any spilt product on your vehicle immediately
Watch out for damage to packaging that may occur during the loading or unloading
Do not allow any dangerous goods to overhang the vehicle
Wear any required PPE during loading and unloading or in the likely event of a risk
Stow the cargo securely. Large packages should be stowed individually.
If delivering a part load, make sure the remaining load is securely stowed
Ensure that gas cylinders are transported in their correct position, well secured and if necessary, in a cradle
Never exceed the weight limits of the vehicle
Check any segregation requirements and ensure that adequate measures for the segregation are in place and effective
Markings
The consignor is responsible for correctly marking and labelling packages. Generally, all packages unless otherwise stated should show the UN number and the relevant class label. Markings must be readily visible and legible and able to withstand open weather exposure. Classes 1, 2 & 7 show the proper shipping name. Class 2 also shows the date of the next inspection due. If salvage packaging is used the word SALVAGE must be marked.
Overpacks may be used to protect or contain and consolidate several packages. When used, unless the UN numbers and class labels are visible, UN numbers and labels representing the packages must be shown on the overpack. The word OVERPACK must be written on the overpack. Orientation arrows may be needed on two opposite sides. The environmentally hazardous substance mark must be shown on packages containing environmentally hazardous substances with the exception of packages containing 5 litres or kg or less.
Orientation arrows need to be shown on:
Combination packages containing liquids
Single packages fitted with vents
Cryogenic receptacles for liquified gases
Machinery or apparatus containing liquid dangerous goods when it is required to ensure it remains in its intended orientation.
The markings may be black or red. The border is left optional.
Warning sign to be shown when dangerous goods are used on a vehicle for cooling or conditioning
Warning sign for the carriage of lithium batteries:
Labels are required on packages:
A minimum size of 100mm x 100mm
The primary and up to two subsidiary classes may be shown
When more than one is required, they shall be shown next to each other
If a package is of an irregular shape and the labels cannot be satisfactorily attached, a securely affixed tag or other means may be used
Be placed so that they are not covered or obscured
Be able to withstand open weather exposure without substantial reduction in effectiveness
Vehicle markings
Transport units carrying dangerous goods shall show orange coloured plates at the front and rear.
The size of the plates are 40 x 30cm with a 15mm black border
The material shall be weather resistant
The plate stays attached in 15 minutes of fire
Remain fixed irrespective of the orientation of the vehicle
May have a black line through the middle
Containers
These show the class placard on all four sides, with subsidiary classes up to 2 classes. The transport unit displays orange plates front and rear. The placards are 250mm x 250mm. If folding placards are used, they shall be designed and secured so they cannot come loose during carriage, including impacts or unintentional actions.
Marking Bulk Vehicles (unpackaged, loose dangerous goods)
UK Domestic (CDG):
Plain orange plate on the front, with hazard warning panels both sides and rear.
ADR
Orange plates front and rear with the Hazard Identification Number and the UN number. The class placard (and up to 2 subsidiaries) on the sides and rear.
Vehicles carrying marked up containers have plain orange plates front and rear, the container being marked all four sides.
IDGM Markings
As these are a higher standard of rules (with lower thresholds for dangerous goods), the markings may be used as part of the vehicle marking. As such, IMDG marked vehicles may be marked slightly differently. The main class placard and subsidiaries are shown on all fours sides of containers and unaccompanied trailers. Rigid vehicles have placards on both sides and the rear. If there is more than 4000kg of a particular dangerous goods on board, then the UN number is shown either separately or incorporated in the placard.
The ink or glue on these markings must keep the markings attached for up to three months in sea water.
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