ASTM D8409-21

Standard Guide for Conducting Stacking Tests on UN Packagings Using Guided or Unguided Loads

SIGNIFICANCE AND USE
4.1 This guide is intended to provide a standardized method and a set of basic instructions for performing stack testing on UN packaging designs using either guided or unguided top loads. This guide provides the suggested minimum information that should be documented when conducting stacking test and provides information for recommended equipment.  
4.2 All packaging design types other than bags must be subjected to a stacking test. Packagings subject to the stacking test must be capable of withstanding a superimposed top load of a specified minimum mass for a specified period of time without failure as these parameters are defined in the regulations. The test is not intended to determine the absolute top load capability of a packaging.  
Note 1: When quantification of box compression strength is desired for determining stacking strength or for design purposes use Test Method D642 and conditioning as recommended in 4.5.  
4.3 Design qualification testing procedures are intended, as explicitly stated in the HMR, to be the minimum performance capability levels for packaging manufactured to transport Hazardous Materials under conditions normally incident to transportation.  
4.4 The HMR tests are designed to be gross package capability evaluations that can be performed in a similar manner in all parts of the world, but under circumstances with some variance in test facility capabilities. This is an intentional feature of the test designs and protocols. The focus of HMR testing is not the determination of quantifiable, comparison data to allow for analytical evaluation.  
4.5 It is recommended that facilities performing the HMR tests consult the guidance on conditioning in the relevant ASTM documents for any particular packaging material as applicable. The following conditioning documents, Practices D4332 and D685, are commonly used.
SCOPE
1.1 This guide is intended to provide a standardized method and a set of basic instructions for conducting stacking tests on United Nations (UN) non-bulk, intermediate bulk container (IBC), and Large Packagings. Using guided or unguided loads in accordance with the U.S. Department of Transportation Title 49 Code of Federal Regulations (CFR) and the UN Recommendations on the Transport of Dangerous Goods (“The Orange Book”). The combination or interchange of these regulations will be referred to as the Hazardous Material Regulations (HMR).  
1.2 The Dangerous Goods Regulations require performance tests to be conducted on packaging designs prior to being authorized for use. The regulations do not include standardized procedures to accomplish this which can result in differences between testing facilities. The purpose of this document is to provide guidance and to establish a set of common practices for conducting stack testing on packagings undergoing UN certification.  
1.3 The user of this guide must be trained in accordance with 49 CFR as required by 172.700 and should be familiar with other applicable hazardous materials regulations such as; International Civil Aviation Organization (ICAO) Technical Instructions for the Safe Transport of Dangerous Goods by Air, the International Maritime Dangerous Goods Code (IMDG Code), and carrier rules such as International Air Transport Association (IATA) Dangerous Goods Regulations.  
1.4 The values stated in SI units are to be regarded as standard. The values given in parentheses after SI units are provided for information only and are not considered standard.  
1.5 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety, health, and environmental practices and determine the applicability of regulatory limitations prior to use.  
1.6 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on...

General Information

• Status: Published
• Publication Date: 14-Oct-2021
• ICS: 55.180.10 - General purpose containers
• Technical Committee: D10 - Packaging
• Drafting Committee: D10.22 - Hazardous Materials

Relations

• Refers: ASTM D4577-19(2023) - Standard Test Method for Compression Resistance of a Container Under Constant Load
• Effective Date: 01-Oct-2023
• Refers: ASTM D4577-19 - Standard Test Method for Compression Resistance of a Container Under Constant Load
• Effective Date: 01-Apr-2019
• Refers: ASTM D4577-05(2018) - Standard Test Method for Compression Resistance of a Container Under Constant Load
• Effective Date: 01-Oct-2018
• Refers: ASTM D4332-13 - Standard Practice for Conditioning Containers, Packages, or Packaging Components for Testing
• Effective Date: 15-Mar-2013
• Refers: ASTM D685-12 - Standard Practice for Conditioning Paper and Paper Products for Testing
• Effective Date: 01-Nov-2012
• Refers: ASTM D996-10a - Standard Terminology of Packaging and Distribution Environments
• Effective Date: 01-Dec-2010
• Refers: ASTM D4577-05(2010) - Standard Test Method for Compression Resistance of a Container Under Constant Load
• Effective Date: 01-Aug-2010
• Refers: ASTM D642-00(2010) - Standard Test Method for Determining Compressive Resistance of Shipping Containers, Components, and Unit Loads
• Effective Date: 01-Aug-2010
• Refers: ASTM D4919-03(2008) - Standard Specification for Testing of Hazardous Materials Packagings (Withdrawn 2017)
• Effective Date: 01-Oct-2008
• Refers: ASTM D4332-01(2006) - Standard Practice for Conditioning Containers, Packages, or Packaging Components for Testing
• Effective Date: 01-Nov-2006
• Refers: ASTM D4577-05 - Standard Test Method for Compression Resistance of a Container Under Constant Load
• Effective Date: 01-Oct-2005
• Refers: ASTM D642-00(2005) - Standard Test Method for Determining Compressive Resistance of Shipping Containers, Components, and Unit Loads
• Effective Date: 01-Apr-2005
• Refers: ASTM D642-00(2005)e1 - Standard Test Method for Determining Compressive Resistance of Shipping Containers, Components, and Unit Loads
• Effective Date: 01-Apr-2005
• Refers: ASTM D996-04 - Standard Terminology of Packaging and Distribution Environments
• Effective Date: 01-Apr-2004
• Refers: ASTM D4919-03 - Standard Specification for Testing of Hazardous Materials Packagings
• Effective Date: 10-Apr-2003

Overview

ASTM D8409-21: Standard Guide for Conducting Stacking Tests on UN Packagings Using Guided or Unguided Loads provides a uniform method and essential guidance for performing stack testing on United Nations (UN) packaging designs. This standard supports regulatory compliance with the U.S. Department of Transportation Title 49 Code of Federal Regulations (49 CFR) and the UN Recommendations on the Transport of Dangerous Goods (the “Orange Book”). The guidance covers non-bulk, intermediate bulk containers (IBCs), and Large Packagings intended for hazardous materials transport.

This standard ensures that all relevant packaging types, except bags, are subjected to stacking tests to demonstrate their ability to withstand required top loads during typical transport conditions. The protocol described in ASTM D8409-21 is essential for manufacturers, testing facilities, and regulatory bodies seeking to maintain consistency and reliability in hazardous materials packaging testing worldwide.

Key Topics

• Stacking Test Procedures: Outlines standardized instructions for conducting stacking (top load) tests on UN packagings, covering both guided (fixed platen) and unguided (floating platen or “dead load”) load methods.
• Regulatory Compliance: Clarifies interrelation with Hazardous Materials Regulations (HMR), including 49 CFR, UN Recommendations, ICAO, IATA, and IMDG codes.
• Specimen Preparation and Conditioning: Details standards for specimen selection, filling, closure, and pre-test conditioning using relevant ASTM practices (D4332, D685).
• Minimum Load Calculations: Provides equations for determining required top loads, addressing stacking height, package mass, and regulatory specifications, with guidance on the handling of solids and liquids.
• Equipment and Apparatus: Recommends the use of calibrated closing tools, compression systems, load spreaders, and appropriate measuring devices for accurate and safe testing.
• Reporting: Specifies required documentation, including full test records, conditions, package descriptions, and outcomes, ensuring traceability and reproducibility of results.
• Safety and Environmental Considerations: Advises users to establish appropriate safety, health, and environmental practices in line with applicable regulations.

Applications

• Packaging Design Qualification: Essential for manufacturers certifying new UN packagings for hazardous materials in compliance with global regulations.
• Periodic Retesting: Facilities can use dynamic compression testing, as permitted by regulations, for recurring packaging qualification and maintenance of certification.
• Global Hazardous Material Logistics: Assists companies involved in cross-border transport of hazardous goods to implement consistent packaging standards, reducing risk and ensuring regulatory acceptance.
• Transport and Storage Safety: Supports the verification of packaging strength for stacking, vital to minimize the risk of package failure during storage, handling, and multimodal transportation.
• Customs and Compliance Checks: Serves as a reference document for inspectors and regulators evaluating the suitability of packaging used in the transport of dangerous goods.

Related Standards

Organizations using ASTM D8409-21 should also reference the following standards and regulations for comprehensive compliance and best practices in packaging and testing:

• ASTM D642: Test Method for Determining Compressive Resistance of Shipping Containers, Components, and Unit Loads
• ASTM D4332: Practice for Conditioning Containers, Packages, or Packaging Components for Testing
• ASTM D685: Practice for Conditioning Paper and Paper Products for Testing
• ASTM D996: Terminology of Packaging and Distribution Environments
• ASTM D4577: Test Method for Compression Resistance of a Container Under Constant Load
• ASTM D4919: Guide for Testing of Hazardous Materials Packagings
• ISO 2234: Packaging - Complete, filled transport packages - Stacking tests using static load
• ISO 16495: Packaging - Transport packaging for dangerous goods - Test methods
• 49 CFR Parts 100-185: U.S. Code of Federal Regulations for hazardous materials transport
• UN Model Regulations: UN Recommendations on the Transport of Dangerous Goods
• IATA Dangerous Goods Regulations, ICAO Technical Instructions, IMDG Code

By following ASTM D8409-21 and its associated referenced documents, organizations can confidently design, test, and qualify packaging for hazardous materials, ensuring safety and regulatory compliance in global transport.

Standards Content (Sample)

This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the
Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
Designation: D8409 − 21
Standard Guide for
Conducting Stacking Tests on UN Packagings Using Guided
or Unguided Loads
This standard is issued under the fixed designation D8409; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision.Anumber in parentheses indicates the year of last reapproval.A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
1. Scope responsibility of the user of this standard to establish appro-
priate safety, health, and environmental practices and deter-
1.1 Thisguideisintendedtoprovideastandardizedmethod
mine the applicability of regulatory limitations prior to use.
and a set of basic instructions for conducting stacking tests on
1.6 This international standard was developed in accor-
United Nations (UN) non-bulk, intermediate bulk container
dance with internationally recognized principles on standard-
(IBC), and Large Packagings. Using guided or unguided loads
ization established in the Decision on Principles for the
inaccordancewiththeU.S.DepartmentofTransportationTitle
Development of International Standards, Guides and Recom-
49 Code of Federal Regulations (CFR) and the UN Recom-
mendations issued by the World Trade Organization Technical
mendations on the Transport of Dangerous Goods (“The
Barriers to Trade (TBT) Committee.
Orange Book”). The combination or interchange of these
regulations will be referred to as the Hazardous Material
2. Referenced Documents
Regulations (HMR).
1.2 The Dangerous Goods Regulations require performance
2.1 ASTM Standards:
tests to be conducted on packaging designs prior to being
D642Test Method for Determining Compressive Resistance
authorizedforuse.Theregulationsdonotincludestandardized
of Shipping Containers, Components, and Unit Loads
procedures to accomplish this which can result in differences
D685Practice for Conditioning Paper and Paper Products
between testing facilities. The purpose of this document is to
for Testing
provideguidanceandtoestablishasetofcommonpracticesfor
D996Terminology of Packaging and Distribution Environ-
conducting stack testing on packagings undergoing UN certi-
ments
fication.
D4332Practice for Conditioning Containers, Packages, or
Packaging Components for Testing
1.3 The user of this guide must be trained in accordance
D4577Test Method for Compression Resistance of a Con-
with 49 CFR as required by 172.700 and should be familiar
tainer Under Constant Load
with other applicable hazardous materials regulations such as;
D4919Guide for Testing of Hazardous Materials (Danger-
International Civil Aviation Organization (ICAO) Technical
ous Goods) Packagings
InstructionsfortheSafeTransportofDangerousGoodsbyAir,
the International Maritime Dangerous Goods Code (IMDG
2.2 ISO Standards:
Code), and carrier rules such as International Air Transport
ISO2234Packaging–Complete,filledtransportpackages–
Association (IATA) Dangerous Goods Regulations.
Stacking tests using static load
ISO 16495Packaging – Transport packaging for dangerous
1.4 The values stated in SI units are to be regarded as
goods – Test methods
standard. The values given in parentheses after SI units are
providedforinformationonlyandarenotconsideredstandard.
1.5 This standard does not purport to address all of the
safety concerns, if any, associated with its use. It is the For referenced ASTM standards, visit the ASTM website, www.astm.org, or
contact ASTM Customer Service at [e-mail]. For Annual Book of ASTM
Standards volume information, refer to the standard’s Document Summary page on
ThisguideisunderthejurisdictionofASTMCommitteeD10onPackagingand the ASTM website.
is the direct responsibility of Subcommittee D10.22 on Hazardous Materials. Available from International Organization for Standardization (ISO), ISO
Current edition approved Oct. 15, 2021. Published December 2021. DOI: Central Secretariat, Chemin de Blandonnet 8, CP 401, 1214 Vernier, Geneva,
10.1520/D8409_D8409M-21. Switzerland, https://www.iso.org.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
D8409 − 21
2.3 Federal Standard: load. The load spreader shall extend to the outside edge of the
U.S. Department of Transportation Code of Federal Regu- perimeter or beyond the perimeter of the test specimen.
lations Title 49, Transportation (49 CFR) Parts 100-185
3.2.7 packagings, n—receptacles and any other components
2.4 UN Standard:
or materials necessary for the receptacle to perform its con-
UN United Nations Recommendations on the Transport of
tainment function in conformance with the minimum require-
DangerousGoods,ModelRegulations(UNOrangeBook)
ments of the HMR; and includes non-bulk, IBC, and Large
2.5 IATA Standard:
Packagings.
IATA International Air Transport Association (IATA) Dan-
3.2.8 stacking test (top load compression test), n—a test
gerous Goods Regulations
designed to ascertain the performance capability of a packag-
2.6 ICAO Standard:
ing under top load compressive forces in storage or transpor-
ICAO Technical Instructions for the Safe Transport of
tation. It is a required design type test for all non-bulk
Dangerous Goods by Air
packagings except bags, and all IBCs intended to be stacked.
2.7 IMDG Standard:
3.2.9 unguided load, n—a constant top loading test per-
International Maritime Dangerous Goods Code (IMDG
formed with floating (swivel) platen compression machines or
Code)
a “dead load” (constant load) mass applied in manner that
3. Terminology
would allow the stack load to tip over in the event of excess
deformation or collapse of the packaging. Floating platens
3.1 Definitions:
swivel to maintain constant load on parts of the packaging that
3.1.1 General definitions for packaging and distribution are
are deforming under pressure.
found in Terminology D996.
3.2.9.1 Discussion—Additional packaging terms and defini-
3.2 Definitions of Terms Specific to This Standard:
tions specific to the regulations are located in 49 CFR, Section
3.2.1 deflection, n—amount of vertical deformation in the
171.8, and the Orange Book, Section 1.2.1.
heightofthepackageunderthetestloadduringthetestperiod.
3.2.2 dynamic compression test, n—a top loading compres-
4. Significance and Use
sion test performed using a machine capable of applying a
4.1 Thisguideisintendedtoprovideastandardizedmethod
dynamic top loading on a package. This test is performed in
and a set of basic instructions for performing stack testing on
conformance with Test Method D642 and the regulations as
UN packaging designs using either guided or unguided top
applicable.
loads.Thisguideprovidesthesuggestedminimuminformation
3.2.3 guided load, n—a static top loading test performed
that should be documented when conducting stacking test and
with fixed platen compression machines or in a “dead load”
provides information for recommended equipment.
stack arrangement where the packaging and weight stack are
constrained from tipping due to deformation or collapse of the 4.2 All packaging design types other than bags must be
packaging. subjected to a stacking test. Packagings subject to the stacking
test must be capable of withstanding a superimposed top load
3.2.4 intermediate bulk container (IBC), n—a rigid or flex-
of a specified minimum mass for a specified period of time
ible portable packaging, other than a cylinder or portable tank,
without failure as these parameters are defined in the regula-
which is designed for mechanical handling, has volumetric
tions. The test is not intended to determine the absolute top
capacity of not more than 3000 L and includes: flexible,
load capability of a packaging.
composite, and rigid IBCs.
3.2.5 large packaging, n—a packaging that contains articles
NOTE 1—When quantification of box compression strength is desired
for determining stacking strength or for design purposes use Test Method
or inner packagings, which is designed for mechanical
D642 and conditioning as recommended in 4.5.
handlings, exceeds 400 kg net mass or has a volumetric
capacity greater than 450 L but not more than 3000 L. 4.3 Design qualification testing procedures are intended, as
explicitly stated in the HMR, to be the minimum performance
3.2.6 load spreader, n—rigid plate that spreads the stack
capability levels for packaging manufactured to transport
loadacrosstheentiretopsurfaceareaofthepackageunderthe
Hazardous Materials under conditions normally incident to
transportation.
Available from Superintendent of Documents, U.S. Government Printing
4.4 The HMR tests are designed to be gross package
Office, Washington, DC 20402-9371 (website: https://www.phmsa.dot.gov/phmsa-
regulations).
capability evaluations that can be performed in a similar
Available from the UN Economic Commission for Europe, Information
manner in all parts of the world, but under circumstances with
Service, Palais des Nations, CH-1211 Geneva 10 Switzerland (website: http://
somevarianceintestfacilitycapabilities.Thisisanintentional
www.unece.org/trans/danger/danger.htm).
Available from the International Air Transport Association (IATA), 800 Place feature of the test designs and protocols. The focus of HMR
Victoria PO Box 113 Montreal - H4Z 1M1 Quebec - Canada (website: http://
testing is not the determination of quantifiable, comparison
www.iata.org).
data to allow for analytical evaluation.
Available from the International Civil Aviation Organization, (ICAO) 999
University Street, Montréal, Quebec H3C 5H7, Canada (website: http://
4.5 It is recommended that facilities performing the HMR
www.icao.org).
tests consult the guidance on conditioning in the relevant
Available from the International Marine Organization (IMO, 4 Albert
Embankment, London, SE1 7SR United Kingdom (website: http://www.imo.org). ASTM documents for any particular packaging material as
D8409 − 21
applicable. The following conditioning documents, Practices specimens must be empty and unsealed. The dynamic com-
D4332 and D685, are commonly used. pression test should be conducted in accordance with Test
Method D642.
5. Apparatus
7. Conditioning
5.1 Closing equipment such as; torque wrenches, torque
7.1 Fordesignqualificationtesting,theminimumcondition-
meters, lid presses, cover/closure crimping tools, etc., to close
ing duration for paper or fiberboard packagings is 24 hours
the container as for transport.
prior to testing. Unless testing is conducted in the conditioning
5.2 Top Load Equipment—Constant (dead) load weights or
atmosphere, it is recommended the test start as soon as
mechanical compression system (machine), such as those
possible, but no more than 15 minutes after removing the
described in Test Method D4577 or Test Method D642.
packaging test specimen from the conditioning atmosphere.
5.3 Stacking fixture (optional) may be used to aid in
NOTE 2—When quantification of box compression strength is desired
applying force load, aligning weights, or improve safety if
for determining stacking strength or for design purposes, more fully
stack load weights should topple
defined conditioning is advisable. For quantifying box stacking strength,
it is recommended using conditioning as specified in Practices D4332 and
5.4 Load spreader used as necessary to ensure even distri-
D685 (see 4.4 and 4.5).
bution of the top load.
7.2 It is recommended to condition fiberboard packagings
5.5 Measuring device appropriate to the task if needed.
priortotestinginaccordancewiththeconditioningatmosphere
5.6 Closing equipment, top load equipment, and measuring specified in Practices D4332 and D685. These ASTM proce-
devices shall be calibrated as necessary. dures recommend conditioning fiberboard and paper for a
minimum of 72 hours.
6. Sampling, Test Specimens, and Test Units
7.3 Conditioning of specific packaging design types in
accordance with the applicable regulation as outlined in 49
6.1 Visually inspect packaging(s) to be tested for consis-
tency with closing instructions and any defects. Verify all CFR is identified in Table 1.
closures, plugs, gaskets, accessories, etc. match the closing
8. Calculating Load
instructions. Determine if the container has a properly formed
sealing surface (record any blemishes or defects). Examine for
8.1 All calculations for minimum top load should be per-
and record any damage which might invalidate the test.
formedusingSIunits,wheretheresultsarestatedinkilograms
before conversion to other units of measure is made.
6.2 Numberofspecimensasrequiredbycurrentregulations
being used for testing. These must be randomly selected
8.2 When no rounding requirements are provided, it is
specimens.
recommended to round up to the nearest tenth at each step
6.2.1 Packagings (Non-Bulk)—Threespecimensisthemini-
when calculating the minimum load.
mum required.
8.2.1 The steps to calculating the minimum load would
6.2.2 IBCs and Large Packagings—One specimen is the
include:
minimum required.
8.2.1.1 Step 1—Thecalculationofthenumberofcontainers,
8.2.1.2 Step 2—Thecalculationofthemassofthecontainer,
6.3 Prepare the packaging for testing, as specified by the
and
current regulations being utilized for the specific design type.
8.2.1.3 Step 3—The calculation of the minimum load.
When the specimen is required to be filled for testing, it shall
be closed and secured in the same manner as for transport.
NOTE 3—To calculate the absolute minimum, do not round until all
6.3.1 The fill capacity for single or inner packagings of calculations are complete. Accuracy should be reflected in the capability
of the equipment used.
non-bulk and inner packagings of Large Packagings is:
6.3.1.1 Solids must be filled to not less than 95 % of
8.3 For non-bulk, the load is the mass of filled like-
maximum capacity.
packagings that could be stacked on top of the test specimen
6.3.1.2 Liquids must be filled to not less than 98 % of
during transport to the equivalent height of 3 m.
maximum capacity. 8.3.1 Calculation of top load for a non-bulk packaging
6.3.1.3 Non-bulk combination packagings prepared for the
tested with solids or liquids is:
stacking test may also be prepared without their inner
MinimumTopLoad 5 n 2 1 3w (1)
~ !
packagings,unlessitwouldinvalidatethetest.Packagingsmay
where:
be tested empty.
6.3.2 IBCs and Large Packagings, except flexible design
n = minimum numb
...