Handling and shipping hazardous materials is serious business. When toxic chemicals, combustible gases, explosive solids and other dangerous goods are transported, lives and property are at risk if something goes wrong. Just ask the residents of Lac-Mégantic, Quebec who lost much of their downtown when railway tank cars carrying crude oil derailed and exploded in 2013. Or the Alabama community exposed to toxic fumes when a truck carrying chlorine gas crashed in 2005.

Incidents like these underscore why extensive training and precautions are mandatory when dealing with hazardous materials – commonly shortened to “hazmat.” Companies that ignore or skimp on proper hazmat education set themselves up for tragedy. Beyond the human toll, violations bring stiff fines and lawsuits that quickly send violators into bankruptcy.

With so much on the line, anyone involved in transporting hazmat should understand the legally-mandated training requirements. You’ll also learn smart tips for sustaining a compliant, safety-focused hazmat training program. Let’s get started.

Defining Hazardous Materials

Hazardous materials are substances posing significant risks to health, safety, property or the environment during handling and transportation. But what exactly constitutes “significant risk?”

The U.S. Pipeline and Hazardous Materials Safety Administration (PHMSA) provides specifics in their Hazardous Materials Regulations (HMR). As of 2022, hazmat is defined as any of the following:

– Explosives 

– Gases (compressed, liquefied, dissolved under pressure or refrigerated)

– Flammable and combustible liquids 

– Flammable solids

– Substances liable to spontaneous combustion

– Substances that emit flammable gases when wet

– Oxidizers and organic peroxides

– Toxic substances and infectious substances

– Radioactive material 

– Corrosives

– Miscellaneous hazardous materials/products, substances, or organisms

Hundreds of common materials qualify as hazmat. Just a few examples are batteries, paints, household cleaners, pesticides, asbestos, and industrial/manufacturing chemicals. Specific regulations apply to training, classifying, packaging, marking, labeling and transporting these materials.

Hazmat Employee Training Requirements

The HMR mandates that anyone who performs hazmat job functions must receive training on how to safely carry out their responsibilities. At a minimum, hazmat employees must complete the following core training:

General Awareness Training

– Covers basic hazmat knowledge for recognizing and identifying dangerous goods.

– Provides a working understanding of hazmat regulations and protocols for safe handling and transport.

– Introduces trainees to hazmat communication standards, such as shipping documents, package markings and labels.

– Explains what to do in hazmat emergencies, such as spills or releases.

– Duration: Usually 90 minutes to 2 hours

Function-Specific Training

– Focuses on the specific hazmat functions each employee performs.

– Covers step-by-step procedures to safely and compliantly carry out job duties. 

– Often utilizes hands-on exercises with actual hazmat packages.

– Duration: Varies based on number of functions trained.

Safety Training

– Reviews immediate methods for avoiding harm when working with hazmat, such as using personal protective equipment (PPE).

– Teaches emergency response procedures for different types of hazmat incidents.

– Explains how to safely clean up small hazmat spills or leaks.

– Covers protocols for hazmat security and protecting packages from damage and tampering.

– Duration: Approximately 1 hour.

Security Awareness Training

– Provides knowledge on security risks associated with hazmat transport.

– Introduces methods for keeping hazmat shipments secure. 

– Teaches how to identify and report security threats or vulnerabilities.

– Explains protocols for communicating with authorities during hazmat emergencies.

– Duration: Approximately 30 minutes.

In summary, hazmat employees must have baseline knowledge of general hazmat regulations and protocols, understand how to safely perform their specific duties, respond appropriately to hazmat emergencies, and keep hazmat secure during transport. PHMSA estimates the complete training regimen takes around 6 hours.

Offering and Verifying Hazmat Training

In-house Training

Many companies choose to conduct hazmat training in-house. This allows you to tailor the content to your organization’s specific policies, procedures and products. However, the training must still align with the HMR core requirements above.

Deliver training through classroom sessions, e-learning courses, videos, hands-on exercises or a combination. Make sure training materials and instructions are available in the languages your employees speak.

Assign someone knowledgeable about the regulations to oversee your hazmat training program. They should document the training and keep records for a minimum of 3 years. Refresh and update internal training materials at least every 2 years.

Third-Party Training

An alternative is to hire third-party hazmat training providers to conduct the training. This avoids the effort of developing and updating in-house training. Look for well-established training firms with experience delivering PHMSA-compliant hazmat education specific to your industry and operational needs.

Ask potential providers about their instructor qualifications, training formats offered, languages supported and quality control measures for keeping material up-to-date. Also find out what documentation they supply once training is completed.

Documenting Training

No matter where training takes place, detailed documentation must prove employees completed all required courses. Records should include:

– Employee name and hazmat job functions

– Course descriptions, duration and dates of training  

– Training provider name 

– Certification that the employee completed the training and is competent to perform their duties

– Name and signature of the training coordinator 

Make sure employees renew training as required and are not allowed to perform hazmat job functions without proper documentation. We’ll discuss hazmat training renewal coming up next.

Renewing and Updating Hazmat Training 

To stay current on regulations and safety protocols, hazmat employees must periodically renew their training. Refresher training intervals depend on the type of course:

– GeneralAwareness: Every 3 years

– Function-Specific: Every 2 years

– Safety: Every 3 years 

– Security Awareness: Every 3 years

If hazmat regulations change or your company implements new policies/procedures between renewal intervals, provide updated training right away. The same thorough documentation standards apply to refresher courses.

Training Requirements for Different Job Functions

While all hazmat employees need training, some roles have additional requirements. Here’s a breakdown of key training responsibilities by job function:

Hazmat Employees

Hazmat employees are people who directly affect hazmat transportation safety, such as:

– Packing hazmat

– Labeling packages

– Preparing shipping papers

– Loading/unloading packages

– Describing hazmat procedures to customers

At minimum, they need the 4 core training types covered earlier. Those handling multiple hazard classes may require more in-depth function-specific training.

Hazmat Handlers  

Hazmat handlers work in transportation but don’t directly manage packages. Their job indirectly impacts hazmat safety. Examples include:

– Supervisors

– Dispatchers  

– Dock foremen

– Warehouse staff

– Mechanics 

General awareness training provides the hazmat knowledge handlers need. They are exempt from the other 3 core training courses.

Hazmat Carriers

Hazmat carriers are companies that transport hazardous materials, either via highway, rail, air or water. They must provide general awareness, function-specific, safety and security training to hazmat employee personnel such as: 

– Sales representatives

– Operations managers

– Dispatchers/customer service

– Dock supervisors  

– Drivers

– Mechanics

Carriers must also confirm hazmat drivers have the CDL and endorsements to operate vehicles transporting dangerous goods.

Hazmat Drivers

In addition to completing the 4 main hazmat training courses, drivers must hold a commercial driver’s license (CDL) with a Hazmat (H) endorsement. To qualify for the CDL-H, drivers must pass a specialized written hazmat test. They must also undergo background vetting and a federal Transportation Security Administration (TSA) threat assessment.

CDL-H holders must then retake and pass the written hazmat exam every 4 years to renew the endorsement. Some states may require more frequent testing.

Penalties and Fines for Non-Compliance

Violating federal hazmat regulations carries severe civil and criminal penalties. Companies can incur fines up to $75,000 per violation per day, with each untrained employee counting as a separate violation. 

In cases of “gross negligence” that wilfully cause death, serious illness, severe injury or substantial property damage, fines can reach $250,000 and responsible parties may face imprisonment up to 15 years.

Beyond financial penalties, improper hazmat training that results in accidents can seriously impact an organization through:

– Harm to personnel, property and the public

– Environmental remediation costs

– Lawsuits and damage claims

– Loss of business licenses or operational permits  

– Reputational damage

Simply put, non-compliance is too risky and expensive compared to the investment of training time and resources.

Tips for Maintaining Compliance

– Document every phase of your hazmat training program, from needs assessment to course delivery and renewals.

– Centralize training records for easy and regular review. Make sure no employees slip through the cracks.

– Update training any time regulations change. Don’t wait for renewal deadlines.  

– Ensure new hires receive training before starting hazmat job duties.

– Confirm that supervisors and managers also complete training relevant to their oversight role. 

– Offer training in formats accessible to all personnel. Provide materials in multiple languages if needed.

– Consider training software solutions that simplify tracking and sending automated reminders for renewals. 

– Include hazmat training compliance in internal audits and inspections.

By making hazmat education a priority across your organization, you protect your people, customers and the public while avoiding fines.

Conclusion

Mishandling hazardous materials carries high stakes for health, safety and environmental contamination. Skilled employees are the first line of defense. 

From facility workers to carriers to drivers, anyone involved in shipping dangerous goods must have hazmat training tailored to their role. This comprehensive education grounded in PHMSA regulations enables the safe, compliant transport of hazmat.

An ongoing training program with accurate record keeping helps sustain knowledge and best practices. By continually educating staff and staying current on evolving regulations, organizations reduce risk, avoid penalties and instill a culture of responsibility across the hazardous materials supply chain.