Transporting hazardous materials (Hazmat) is one of the most strictly regulated areas of trucking. Because Hazmat shipments carry the risk of fires, explosions, toxic exposure, and environmental damage, FMCSA enforces extremely detailed rules under 49 CFR Parts 107, 171, 172, 173, 174, 175, 176, and 177. Even one mistake in placarding, paperwork, training, or packaging can result in major fines, Out-of-Service (OOS) orders, or a full DOT investigation.
Hazmat violations are also among the most expensive FMCSA citations. Some fines reach over $75,000 per violation and increase if the material poses severe risk.
This guide explains the most common Hazmat violations, the official FMCSA codes, real-world risks, penalties, and how fleets can stay compliant.
Why Hazmat Compliance Matters More Than Ever
The FMCSA has increased enforcement of hazardous materials transportation due to rising incidents involving lithium batteries, flammable liquids, corrosives, and toxic chemicals. These materials are essential to supply chains, but one compliance failure can lead to catastrophic outcomes for drivers, the public, and the environment.
Key reasons Hazmat compliance is stricter in 2025:
- More electronic devices mean more high-risk lithium battery transport
- Increased DOT inspections focused on cargo securement and placarding
- Carriers are now required to maintain precise documentation trails
- States have expanded Hazmat enforcement during roadside inspections
- Civil penalties have increased across all major Hazmat categories
Because of this, carriers must ensure that all Hazmat employees, including drivers, dispatchers, loaders, and supervisors, understand their regulatory responsibilities.
Common Hazardous Materials Violations (Detailed With CFR Codes)
Below are the most frequent Hazmat violations based on FMCSA enforcement data. Each one includes the corresponding violation code, common causes, and real risk factors.
2.1 Improper or Missing Placards
Violation Code: 172.504(a)
Placards are essential for identifying hazardous cargo in emergencies. Missing, damaged, or incorrect placards are among the top OOS violations for Hazmat carriers.
Common causes:
- Wrong placard for the hazard class
- Placard not visible or obscured by dirt or equipment
- Placard missing on one side of the vehicle
- Incorrect weight threshold calculations
- Using a general placard when specific class placard is required
Why this violation is serious:
Incorrect placarding creates confusion for first responders and can delay emergency action during an accident.
2.2 Improper Marking or Labeling of Packages
Violation Code: 172.300–172.400
Package labels and markings communicate critical handling information such as hazard class, UN number, and orientation.
Common causes:
- Missing UN identification number
- Labels placed in the wrong location
- Faded, damaged, or peeling labels
- Incorrect markings for bulk vs. non-bulk packages
Real-world risk:
Incorrect labels can lead to improper cargo handling, spills, and hazards during loading/unloading.
2.3 Incorrect or Incomplete Hazmat Shipping Papers
Violation Code: 177.817(e)
Shipping papers must include:
- Proper Shipping Name
- Hazard Class
- UN/NA Identification Number
- Packing Group
- Emergency contact number
- Quantity and container type
- Shipper certification
Common mistakes include:
- Using abbreviations instead of proper shipping names
- Missing emergency response phone number
- Incorrect sequence of description
- Shipping papers not within driver’s reach
- No separation between Hazmat and non-Hazmat entries
Incomplete paperwork is one of the fastest ways to receive a violation.
2.4 Hazmat Training Violations
Violation Code: 172.704(c)
Every Hazmat employee must receive:
- General awareness training
- Function-specific training
- Safety training
- Security awareness training
- In-depth security plan training (when required)
Training must be repeated every 3 years, documented, and verified.
Common violations include:
- Expired certificates
- No proof of training on file
- Function-specific training missing
- New employees performing tasks before training
FMCSA views training violations as operational failures, not clerical errors.
2.5 Improper Loading, Unloading, or Securement
Violation Code: 177.834
Hazmat cargo must be secured and handled following specific rules depending on the hazard class.
Common violations:
- Cargo not blocked or braced
- Leaking containers
- Incompatible materials loaded together
- Open or unsecured valves
- Damaged drums or packaging
These violations often lead to OOS orders because they create immediate danger.
2.6 Incompatible Materials Stored Together
Violation Code: 177.848
Certain chemicals react dangerously when combined. Mixing them can cause fires, explosions, or toxic gas release.
Examples of incompatible materials:
- Acids + Cyanides
- Oxidizers + Flammables
- Organic Peroxides + Metals
- Lithium batteries + Flammable liquids
Failure to follow segregation tables is a serious violation.
2.7 Emergency Response Information Missing or Inaccessible
Violation Code: 172.602
Drivers must have immediate access to:
Common causes:
- Documents stored in an overhead compartment
- ERG missing or outdated
- Driver unaware of where papers are
This violation is taken seriously because emergency responders depend on immediate access.
2.8 Hazmat Security Plan Violations
Violation Code: 172.800
A security plan is required for high-risk materials such as:
- Explosives
- Toxic inhalation hazards
- Radioactive materials
- Certain flammables in bulk
Violations occur when:
- Security plan is incomplete
- Not updated annually
- Employees not trained on the plan
2.9 No Hazmat Endorsement on CDL
Violation Code: 383.93(b)(1)
A Hazmat driver must have:
- Valid CDL
- H endorsement
- TSA background check
Drivers without proper credentials cannot transport hazardous materials.
Hazmat Out-of-Service (OOS) Violations
The following violations result in immediate OOS orders:
- Placards missing when required
- Leaking packages (173.24)
- Damaged containers not repaired
- Incompatible materials loaded together
- Unauthorized passengers
- Driver lacking Hazmat endorsement
- Shipping papers missing
- Bulk packages not secured
These violations instantly stop operations and may require remedial actions before the vehicle can move.
Penalties for Hazmat Violations
Hazardous materials penalties are significantly higher than standard DOT penalties.
Typical fines:
- Up to $90,000 per violation for serious breaches
- Up to $550,000 for violations causing injury or death
- $500–$20,000 for paperwork violations
- OOS orders until corrected
Repeat offenders risk:
- Full compliance reviews
- Increased inspections
- Suspension of Hazmat permit
How Fleets Can Prevent Hazmat Violations
Document training, quizzes, and certifications.
The driver should know the exact location.
Use a Hazmat checklist.
Check valves, drums, hoses, and containers.
Either physical or electronic.
Update annually and train employees on it.
