Dangerous Goods Handling Procedures: UK Checklist & Steps

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Moving dangerous goods isn’t hard because the tasks are difficult; it’s hard because the rules are many, fragmented by mode, and unforgiving. A small error in classification, packing, labelling or paperwork can stop a load at the gate, trigger a fine, or create real safety risk. In the UK you must satisfy HSE and the Carriage of Dangerous Goods rules while also meeting ADR, IMDG, IATA and RID — often all at once.

This guide gives you a clear, practical route through that complexity. It distils the regulations into a step‑by‑step procedure you can follow across road, sea, air and rail, with plain‑English explanations, decision points for common exemptions, and a printable checklist you can use on the floor or during audits. The aim is simple: safe, compliant shipments, first time.

You’ll confirm scope and legal framework, classify substances correctly, check limited/excepted quantity options, assign roles and training (including DGSA), control risks, choose compliant packaging, mark and label accurately, prepare mode‑specific documents, store and stage safely, load and secure to the CTU Code, configure vehicles and equipment, plan the journey and notifications, prepare for emergencies, and verify and retain records. Ready to turn requirements into a reliable handling procedure? Let’s start with scope.

Step 1. Confirm your scope and legal framework (UK and international)

Before you touch packaging or paperwork, lock down the legal scope. Decide what you are moving (UN dangerous goods classes 1–9), what role you play (consignor, packer, loader, carrier, consignee), and every transport mode and leg involved (domestic or international). This determines which dangerous goods handling procedures and rule sets apply, and avoids conflicts at modal interfaces and hand‑offs.

  • UK baseline: Carriage of Dangerous Goods and Use of Transportable Pressure Equipment Regulations (CDG/TPED) and HSE guidance.
  • Road: ADR (as implemented in UK law via CDG).
  • Sea: IMDG Code.
  • Air: ICAO Technical Instructions; IATA DGR (often more restrictive; check airline/state variations).
  • Rail: RID.

For multimodal moves, apply each modal code at the relevant leg and follow the most restrictive requirement. Record your scope decision.

Step 2. Identify and classify the substance correctly (UN number, proper shipping name, class, packing group)

Everything else in your dangerous goods handling procedures depends on getting the identity right. Don’t use trade names. Use the official lists to determine the UN number, the exact Proper Shipping Name (PSN), the UN hazard class (1–9) and, where relevant, the packing group (I high danger, II medium, III low).

  • Gather data: Confirm composition and physical state, then consult the official lists (e.g., IATA DGR list of articles/substances; ADR/IMDG indexes).
  • Select the entry: Use the named entry or the correct n.o.s. family when applicable, as shown in the regulations.
  • Fix the PSN and UN number: Copy the wording exactly as listed in the code you’re applying.
  • Assign class and packing group: Use the class 1–9 system; apply PG I/II/III as specified for the entry.
  • Note modal conditions: Capture any packing instructions and quantity limits for the mode (air, sea, road, rail).
  • Document the result: Record UN number, PSN, class and PG for use on labels and documents.

Step 3. Check exemptions and special cases (limited quantities, excepted quantities, lithium batteries, infectious substances, samples)

Once classified, check whether any reliefs or special provisions apply. These can change packaging, marks and paperwork by mode, so confirm eligibility and the exact conditions in the relevant code before you adjust your dangerous goods handling procedures.

  • Limited Quantities (LQ): Confirm the entry is LQ‑eligible for the mode, apply inner/outer quantity limits, use the LQ mark, and follow any mode‑specific stowage/segregation rules.
  • Excepted Quantities (EQ): Verify the EQ code and conditions, use the EQ mark; in air, no Shipper’s Declaration is needed when EQ applies, but the Air Waybill must carry the required details.
  • Lithium batteries: Apply the battery‑specific provisions in the modal code; for air, use the IATA Battery Shipping Regulations and check any state/operator variations.
  • Infectious substances: Use the correct category and packing instructions; IATA’s Infectious Substances Shipping Guidelines provide shipper‑focused detail.
  • Samples/waste: Check the modal “samples” and “waste” provisions; some test or diagnostic samples may qualify for EQ or other reliefs. Record your decisions and reasons.

Step 4. Assign roles, competence and training (including DGSA) and keep records

Define who does what (consignor, packer, loader, carrier, operator) and only allow competent, trained people to perform each function. UK operators must appoint oversight and ensure training is role‑appropriate, current, and evidenced before tasks are undertaken.

  • Appoint a DGSA: From 31 Dec 2022, businesses participating in the carriage of dangerous goods (including packing, loading, filling or unloading) must appoint a Dangerous Goods Safety Adviser to advise, monitor compliance and report.
  • Train by mode and function: Air: IATA DGR training for all who prepare, offer, accept or handle DG; Road: ADR driver certification plus role‑appropriate training for others; Sea/Rail: IMDG/RID function‑specific training.
  • Refresh regularly: IATA requires renewal every two years; HSE recommends refresher training every two years to keep staff current.
  • Control authorisations: Nominate competent persons and supervise new staff until fully trained.
  • Keep records: Maintain training certificates, competence records, DGSA appointment and reports; keep available for inspection and check currency before assigning work.

Step 5. Conduct a risk assessment and set workplace controls (COSHH/DSEAR, segregation, security)

With classification fixed, complete a documented risk assessment for all pre‑transport activities (receiving, picking, decanting, packing, staging and loading). In the UK, assess health exposure under COSHH and fire/explosion risk under DSEAR alongside CDG/ADR duties, then implement proportionate controls and embed them into your dangerous goods handling procedures.

  • Substitute/reduce quantities: Minimise volumes where practicable.
  • Segregate incompatibles: Separate by UN class; never store next to food.
  • Control ignition sources: Apply DSEAR; manage static, hot work and electrics.
  • Engineering controls: Use bunded areas and effective ventilation for vapours/gases.
  • Spill readiness: Provide suitable spill kits and trained responders.
  • PPE and SDS: Specify task‑based PPE; keep SDS accessible at point of use.
  • Safe handling equipment: Maintain forklifts/attachments; use rated securing devices.
  • Security measures: Restrict access, lock stores, verify seals; brief staff on suspicious activity.

Record hazards, controls, responsible persons and review dates; re‑assess on change or after incidents.

Step 6. Select compliant packaging and prepare the pack (UN spec, packing instructions, closures, overpacks)

Packaging choice is not a preference call; it flows directly from your classification, packing group and the mode’s packing instructions. Use only packaging permitted by the relevant code and assemble it exactly as specified. For air, ensure the pack can withstand changes in pressure and temperature and won’t leak; for all modes, the package must be sound, clean and free from contaminants.

  • Choose UN‑spec packaging: Select performance‑tested packaging rated for the assigned packing group and the substance (solids/liquids, inner/outer as applicable).
  • Apply the modal packing instruction: Use the specific PI from ADR/IMDG/RID or ICAO/IATA; observe inner container limits, cushioning, absorbent and quantity per package.
  • Ensure compatibility: Packaging materials must be compatible with the contents; remove any obsolete markings from reused outers.
  • Fit closures correctly: Follow the manufacturer’s closure instructions (caps, gaskets, torque/tape); secure closures so they cannot loosen in transport.
  • Build the pack correctly: Use required inner packagings, liners and dividers; keep ullage/headspace where specified.
  • Manage overpacks properly: If overpacking, keep required marks/labels visible or reproduce them on the overpack and indicate that an overpack is used where the code requires.
  • Respect container limits: Place only permitted dangerous goods in a freight container or ULD for the mode and stow to prevent movement or damage to the pack.

Step 7. Mark and label packages accurately and remove obsolete marks

Marking and labelling is the primary way you communicate hazards through the transport chain, so be precise and consistent with the code you’re following. Build this into your dangerous goods handling procedures so nothing leaves your site with missing, wrong or conflicting information.

  • Apply required marks: Use the exact Proper Shipping Name and UN number as required by the mode.
  • Use correct hazard labels: Affix the class/division labels specified; meet size, colour, symbol and format rules.
  • Add handling marks: Orientation arrows, Limited/Excepted Quantity marks, lithium battery and dry ice marks where applicable.
  • Durable and visible: Labels must be durable, adhesive, on a clean surface, clearly visible and not obscured by straps or wrap.
  • Overpacks: Ensure all mandatory marks/labels remain visible on the outside or are reproduced on the overpack.
  • Language and legacy: Include English, and remove any previous/obsolete markings that no longer apply.
  • Air-specific checks: Verify any IATA state/operator variations before release.

Step 8. Prepare the required documentation and notifications by mode (ADR, IATA, IMDG, RID)

Documentation is the thread that ties your classification, packaging and marks to the carrier’s acceptance. Prepare it against the specific modal code you’re shipping under and verify every data point back to your recorded UN number, Proper Shipping Name, class and packing group. Build these checks into your dangerous goods handling procedures so admin errors don’t stop the consignment at acceptance.

  • Air (IATA/ICAO): Complete a Shipper’s Declaration for Dangerous Goods and the Air Waybill. The declaration must include, among other items, shipper and consignee, Air Waybill number, page count, aircraft limitations, airports of departure/destination, shipment type, nature and quantity of dangerous goods, number/type of packages, packing instruction, authorisations, additional handling information, certification statement, name of signatory, date and signature. Use the IATA Dangerous Goods Checklist at acceptance. Where Excepted Quantities apply, no Shipper’s Declaration is required, but the Air Waybill must carry the required details.
  • Sea (IMDG): Provide dangerous goods documentation in the form and with the particulars required by the IMDG Code; ensure descriptions exactly match the package marks and labels.
  • Road (ADR) and Rail (RID): Issue the transport document with the particulars required by the relevant code for the leg; ensure consistency with marks/labels and packing.

Retain copies of all documents and any acceptance checklists; ensure versions are legible and match the final loaded configuration before release to the carrier.

Step 9. Store and stage consignments safely on site before dispatch (segregation, bunding, ventilation, security)

Before dispatch, treat the staging area as controlled storage. Use a designated DG marshalling zone with signage and supervision. Apply the same segregation, containment and ventilation rules as your store, verify pack integrity, and never position dangerous goods next to food. Build these controls into your dangerous goods handling procedures.

  • Segregate and zone: Separate incompatibles by class and from non‑DG flows.
  • Contain liquids: Use bunded pallets/drip trays; keep containers upright and below stack limits.
  • Control atmosphere: Provide ventilation; exclude ignition sources and hot work.
  • Maintain visibility: Keep pallets stable; don’t obscure marks/labels; orientation arrows upright.
  • Secure and ready: Restrict access; check seals/counts; log location/time; keep SDS and spill kits; quarantine damaged packs.

Step 10. Load, segregate and secure the load (vehicle, CTU, ULD) in line with the CTU Code

Loading is where good preparation succeeds or fails. Apply CTU Code principles—plan, segregate, restrain and verify—to vehicles, intermodal containers and air ULDs. Confirm the load plan matches the documents, then stow to prevent movement and damage under normal transport forces across every leg, and avoid proximity to foodstuffs and known incompatibles.

  • Inspect the unit/vehicle: Clean, dry, structurally sound; serviceable lashing points.
  • Segregate incompatibles: Separate by class; keep dangerous goods away from food.
  • Distribute weight: Heaviest low and central; maintain a stable centre of gravity.
  • Block, brace and lash: Use rated straps, dunnage and chocks to prevent shift.
  • Protect packages: Keep upright per arrows; prevent crushing; shield closures/edges.
  • Verify and seal: Reconcile counts with papers; seal and record seal numbers.

Step 11. Configure the vehicle/container and operator equipment to ADR/IMDG/IATA requirements (placards, equipment, tunnel codes, NOTOC)

Before the unit leaves your site, configure the vehicle, container or ULD to the correct modal standard. This is where placards, safety equipment and operator notifications prove your dangerous goods handling procedures are complete and accepted through the chain. Remove any obsolete markings and verify everything against your classification and documents.

  • ADR (road): Fit orange plates/placards when required by load; carry the ADR‑required vehicle equipment appropriate to the goods; confirm drivers have valid ADR certification; check the consignment’s tunnel restriction code and brief the route accordingly.
  • IMDG (sea): Placard the CTU on all four sides with the correct class labels and, if applicable, the marine pollutant mark; record seal numbers; ensure the load matches the IMDG documentation provided to the carrier/port.
  • IATA/ICAO (air): Ensure any aircraft limitations are respected; complete operator acceptance checks; issue the Notification to Captain (NOTOC) with accurate stow, segregation and quantity details.
  • RID (rail): Apply required placards/marks to wagons/CTUs and provide the carrier with accurate RID particulars aligned to the packages and placards.

Step 12. Plan the journey and communicate with carriers, ports and airports (routing, restrictions, pre-advices)

With the unit configured, lock in a compliant route and the acceptance timings for each leg. For road, verify the ADR tunnel restriction code and any local prohibitions; for air and sea, align your plan with operator/state and port/airport requirements that can be more restrictive. Share accurate data early—this prevents refusals at the gate.

  • Check routing constraints: Validate ADR tunnel codes on the planned route and agree diversion plans if closures occur.
  • Book and pre‑advise carriers: Submit required DG particulars (UN number, Proper Shipping Name, class, packing group, quantities) to the carrier/terminal within their cut‑offs.
  • Air coordination: Pre‑alert the airline with Air Waybill and Shipper’s Declaration data; confirm any IATA state/operator variations and aircraft limitations.
  • Port/terminal notices: Follow port hazardous pre‑advice procedures; obtain gate‑in and stowage instructions consistent with IMDG details.
  • Allow for acceptance checks: Build in time for IATA Dangerous Goods Checklist reviews and any inspections before load close‑out.
  • Brief the driver/handler: Issue the route, tunnel code notes, contact numbers and site instructions for each hand‑off point.

Step 13. Prepare for emergencies and incident response (spill, fire, first aid, reporting)

Even perfect paperwork won’t help if people freeze when something goes wrong. Build practical emergency readiness into your dangerous goods handling procedures so staff know who does what, what to use, and who to call for spills, fires or exposure. Base actions on the SDS, your COSHH/DSEAR assessments, and the applicable modal code.

  • Plan and assign: Issue a simple Emergency Response Plan with roles and 24/7 contacts.
  • Stage equipment: Keep suitable spill kits, PPE, eyewash and first‑aid close to DG areas.
  • Driver/vehicle kit: Ensure ADR‑required equipment is on board and serviceable.
  • Alarm and isolate: Raise the alarm, cordon the area, control ignition sources, ventilate.
  • Contain if trained: Use bunds/absorbents to stop spread; don’t mix incompatibles.
  • Fire response: Only tackle if trained and safe; call Fire & Rescue immediately.
  • Inform responders: Provide SDS and transport particulars (UN, PSN, class, quantity; NOTOC for air).
  • Treat exposure: Follow SDS first‑aid advice; use eyewash/showers; move to fresh air.
  • Report and record: Notify the carrier and competent authorities as required by ADR/IMDG/IATA; log actions.
  • Recover and review: Decontaminate, dispose of waste as DG, and have your DGSA review and improve controls.

Step 14. Verify, retain records and audit performance for continuous improvement

Close the loop before and after each shipment. Build final verification into your dangerous goods handling procedures, retain complete, legible records, and use routine audits to spot drift. Your DGSA should monitor compliance and coach improvements based on data from checks, near‑misses and incidents.

  • Verify before dispatch: Cross‑check UN number, Proper Shipping Name, class/PG, marks/labels and documents match the packed goods; for air, use the IATA Dangerous Goods Checklist at acceptance.
  • Retain the evidence: Keep classification notes, packing instructions used, closure instructions, training/competence records, DGSA appointment, checklists, transport documents and carrier acceptances.
  • Log non‑conformances: Record rejections, packaging damage, mis‑labelling, LQ/EQ mis‑use, and state/operator variation breaches.
  • DGSA oversight: Have the DGSA review trends, advise corrective actions and verify actions are closed.
  • Audit and review: Run periodic internal audits and post‑incident reviews; track KPIs (acceptance failures, near‑misses, spill responses) and update procedures, training and controls accordingly.

Step 15. UK dangerous goods handling checklist (printable summary)

Print this checklist and tick each line before hand‑over. Keep the signed page with your consignment file.

  • Scope: Roles and modes (CDG/ADR/IMDG/IATA/RID) confirmed and recorded.
  • Classification: UN number, PSN, class and packing group fixed.
  • Exemptions: LQ/EQ, lithium, infectious, samples; conditions/marks met.
  • Competence: DGSA appointed; staff training in date and evidenced.
  • Risk controls: COSHH/DSEAR; segregation, ignition control, PPE; SDS at point.
  • Packaging: UN spec per PI; compatible; closures torqued; overpack compliant.
  • Marks/labels: UN/PSN; hazard/handling marks; obsolete removed.
  • Documents: Modal particulars correct; DG declaration/AWB or ADR/RID/IMDG issued.
  • Load/stage: Segregated, bunded, ventilated; CTU Code stow/lash; seals logged.
  • Release: Placards/orange plates/equipment; tunnel code brief; NOTOC; records kept.

What to do next

You now have a clear, end‑to‑end procedure you can run on every shipment. The fastest way to embed it is to test it on a single lane, fix the gaps, then roll it out site‑wide with training and simple checks. Keep the checklist visible, make roles explicit, and use acceptance failures and near‑misses as fuel for improvement—not blame.

  • Pick a pilot: Choose one product/route and run the full procedure and checklist.
  • Assign ownership: Nominate a process owner and publish a training matrix by role.
  • Close the skills gap: Schedule role‑specific IATA/IMDG/ADR/RID training and appoint your DGSA.
  • Prove acceptance: Dry‑run a carrier check (use the IATA Dangerous Goods Checklist for air).
  • Lock in assurance: Set audit dates, KPIs and a simple incident review routine.

Need expert training, coaching or an in‑house rollout plan? Talk to the team at Logicom Hub to make compliance reliable and repeatable.