Shipping of Infectious Substances

Welcome back to this series of modules on biorisk management.

In this lesson, we’ll focus on the safe and secure shipping of infectious substances and biological specimens.

Transporting biological materials is a routine but critical part of laboratory operations. Whether supporting diagnostics, research, or public health response, these materials must be handled with care to protect both people and the environment.

In this lesson, we’ll walk through why materials are transported, the regulations that govern shipping, and the key practices for safe and secure transport.

Let’s begin with why we ship biological materials.

In today’s interconnected world, laboratories often rely on one another. During public health events—such as disease outbreaks or pandemics—samples may need to be sent to specialized or reference laboratories for advanced testing or confirmation.

This collaboration is essential. But it also introduces risk.

Improper shipping can lead to leaks, exposure, and serious safety incidents.

Take a moment to consider what might go wrong during transport. In many cases, failures are preventable. Common issues include fragile containers breaking, lack of leak-proof packaging, missing absorbent materials, incorrect labeling, incomplete documentation, and insufficient training.

Each of these failures increases the likelihood of an incident.

Transport, in this context, refers to moving biological materials outside of a controlled laboratory environment.

Once materials leave containment, they are exposed to public spaces and must be managed with strict safety and security measures.

To support this, a wide range of regulations governs the shipment of biological materials.

These include international agreements, national import and export laws, and transport-specific regulations depending on whether materials are shipped by air, road, rail, sea, or postal service.

It’s important to understand that no single regulation applies universally. Instead, compliance requires awareness of all applicable frameworks.

Air transport, in particular, is highly regulated due to the proximity of hazardous materials to passengers. Organizations such as the International Air Transport Association and the International Civil Aviation Organization establish strict requirements for shipping dangerous goods.

So, what exactly qualifies as a dangerous good?

A dangerous good is any substance capable of posing a risk to health, safety, property, or the environment.

Biological materials fall under Class 6.2—infectious substances.

These are divided into two main categories.

Category A includes substances that can cause life-threatening or fatal disease upon exposure. These represent the highest level of risk.

Category B includes substances that do not meet the criteria for Category A and are considered lower risk.

There is also a third group—exempt specimens—which have minimal likelihood of containing pathogens but must still be packaged to prevent leakage.

Correct classification is essential, as it determines how materials must be packaged, labeled, and documented.

Each classification is assigned a specific UN number and proper shipping name.

For example:
UN 2814 is used for infectious substances affecting humans,
UN 2900 for infectious substances affecting animals,
UN 3373 for Category B materials,
and UN 1845 for dry ice.

These identifiers must be used exactly as specified. Errors can result in shipment rejection.

Now let’s talk about packaging.

The standard approach is known as the triple packaging system.

This includes three layers.

First, a primary container that holds the specimen and is leak-proof.

Second, a secondary container—also leak-proof—with absorbent material to contain any potential leaks.

And third, a rigid outer container that protects the contents and displays all required labels and documentation.

This system is designed to prevent release, even if one layer fails.

Category A and Category B materials both use triple packaging, but Category A requires more robust packaging and additional documentation.

In many cases, materials must be kept cold during transport.

Dry ice is commonly used for this purpose.

However, dry ice is itself classified as a dangerous good and must be labeled and documented separately. When used, both the biological material and the dry ice must be properly declared.

Labeling and documentation are critical components of safe shipping.

Every package must clearly display the shipper and recipient information, the proper shipping name, the UN number, and any applicable hazard labels.

Documentation may include a packing list, an airway bill, and—when required—a shipper’s declaration for dangerous goods.

Accuracy is essential. Even small errors can delay or prevent shipment.

For efficiency, multiple packages may be placed into a larger container known as an overpack.

This outer package must still display all required markings and clearly indicate that it contains multiple shipments.

Beyond packaging and documentation, it’s also important to consider legal and administrative requirements.

Material Transfer Agreements, or MTAs, define how materials can be used, shared, and managed between institutions. These agreements help protect both the sender and the recipient.

Not all transport happens across countries.

Much of it occurs within facilities or between nearby buildings.

Even in these situations, proper containment is necessary. Using sealed, leak-proof containers—and applying triple packaging principles when appropriate—helps reduce the risk of spills and exposure.

Organizations should also establish Standard Operating Procedures for transport.

These procedures should define packaging requirements, emergency response actions, training expectations, and documentation practices.

Personnel involved in transport must know how to respond to incidents, including spills, accidents, or potential exposures.

When shipments arrive, they should be handled carefully.

Documentation should be verified before opening, and packages should be opened in appropriate containment when necessary, such as within a biosafety cabinet.

Security is another critical consideration.

Transport security ensures that materials are protected from loss, theft, or misuse.

This includes selecting reliable couriers, restricting access to shipments, tracking packages during transit, and confirming delivery.

Maintaining a clear chain of custody is equally important.

Every transfer of responsibility should be documented, including names, dates, and times. This creates accountability and traceability throughout the shipping process.

Before any shipment is sent, it’s essential to pause and review.

Confirm the classification of the material.

Ensure the correct packaging has been used.

Verify that all labeling and documentation are complete.

And confirm that any required permits or agreements are in place.

In summary, safe shipping of biological materials depends on proper classification, robust packaging, regulatory compliance, accurate documentation, and strong security practices.

If you are responsible for shipping infectious materials—especially by air—formal certification and training are required to ensure compliance and safety.

Thank you for participating in this lesson.

Please proceed to the quiz to reinforce the key concepts covered in this lesson.