Overpack Rules

IATA DGR Section 7.1.7 — requirements for overpacks containing dangerous goods: definition, marking, labelling, quantity declaration, and restrictions on nesting overpacks.

Quick Summary

- An overpack consolidates one or more DG packages from a single shipper into one handling unit
- The word "OVERPACK" must be marked on the outside (min. 12 mm letters)
- If inner labels are NOT visible, they must be reproduced on the overpack exterior
- Total net quantity per UN number must appear on the DGD
- Overpacks must NOT be nested inside other overpacks

7.1.7 Overpack Requirements

7.1.7.1

Overpack Definition

An overpack is an enclosure used by a single shipper to contain one or more packages, consolidated into a single unit for convenience of handling and stowage. Examples include a box or a pallet with packages secured by strapping or shrink-wrap.

Note: An overpack is NOT a unit load device (ULD). A ULD used as an overpack must meet additional requirements per 7.1.7.4.

7.1.7.2

"OVERPACK" Marking Requirement

The word "OVERPACK" must be marked on the outside of the overpack. The marking must be clearly visible and legible. Minimum letter height: 12 mm. If labels/markings on inner packages are visible through the overpack, the "OVERPACK" marking is still required.

Note: For overpacks containing only Limited Quantities or Excepted Quantities, the word "OVERPACK" is not required IF the labels/markings on inner packages are visible.

7.1.7.3

Inner Package Visibility

If the labels, markings, and UN numbers on inner packages are NOT visible through the overpack, the overpack must be marked with: (a) the word "OVERPACK", (b) the UN number(s) and proper shipping name(s), (c) applicable labels/markings reproduced on the outside, and (d) the name and address of the shipper and consignee (unless already on the Air Waybill).

Note: Each inner package must still comply with all applicable DGR packing, marking, and labelling requirements independently.

7.1.7.4

Total DG Quantity Statement

When an overpack contains packages of dangerous goods, the total quantity of each dangerous good must be stated on the Shipper's Declaration (DGD). The overpack must show the net quantity of each UN number, unless inner package quantities are visible.

Note: If mixed quantities of the same UN number are in the overpack, the total net quantity must be the sum of all inner packages.

7.1.7.5

Label Duplication on Overpack

All hazard labels, handling labels, and the shipper/consignee marks that are required on individual packages must be duplicated on the outside of the overpack, UNLESS these markings/labels on the inner packages are visible from outside. The orientation arrows (if required) must also be duplicated.

Note: Cargo Aircraft Only (CAO) label, if applicable, must always appear on the outside of the overpack regardless of inner package visibility.

7.1.7.6

Multiple Overpacks

An overpack must NOT be placed inside another overpack. Multiple overpacks may be placed onto a single pallet or into a ULD, but each overpack must be individually marked and labelled. Each overpack retains its own identity for documentation purposes.

Note: When multiple overpacks are consolidated on a pallet, the outer consolidation is considered a ULD loading operation, not an overpack.

Common Mistakes

MistakeConsequenceCorrection

Missing "OVERPACK" markingRejection at acceptance check — DGR 9.1.3 non-complianceApply "OVERPACK" in letters at least 12 mm high on the exterior

Labels on inner packages not reproducedEmergency responders cannot identify hazards — DGR 7.1.7.3 violationDuplicate all hazard/handling labels on the overpack exterior

DGD does not state total quantities per UN numberDGD incomplete — acceptance must be refused per 9.3.1Sum all inner package net quantities per UN number on the DGD

Overpack inside another overpackProhibited per 7.1.7.6 — re-pack requiredConsolidate packages into a single overpack or use a ULD

CAO label hidden inside the overpackCAO-only shipment loaded on passenger aircraft — safety breachCAO label must ALWAYS appear on the overpack exterior

Overpack vs. ULD

Overpack

- Prepared by the shipper
- Single shipper only
- Marked "OVERPACK"
- DGD must state total quantities
- Cannot be nested

Unit Load Device (ULD)

- Prepared by operator / ground handler
- May contain shipments from multiple shippers
- Not marked "OVERPACK"
- Segregation rules apply (Table 9.3.A)
- DG packages must remain accessible for inspection

Source: IATA DGR 67th Ed., Section 7.1.7 (p.744, PNG 0776). Cross-references: 5.0.2.11 (DGD overpack entry), 9.1.3 (acceptance check), 9.3.1 (acceptance refusal criteria).