HazMat Tank DOT Inspections: What Fleets Need to Know

Transporting hazardous materials in tank vehicles carries a higher level of risk and regulatory oversight than most other commercial operations. Because of this, DOT inspections involving hazmat tank vehicles are among the most detailed and strictly enforced. Fleets operating in North Carolina and throughout the Southeast must ensure their equipment, documentation, and procedures fully comply with federal and state regulations.

Understanding what inspectors look for during a hazmat tank DOT inspection can help prevent violations, costly fines, and out-of-service orders.

Why HazMat Tank Inspections Are Stricter

Unlike other transport trucks, hazmat tank vehicles transport large volumes of hazardous materials, including flammable liquids, corrosives, gases, and toxic substances. A failure involving a tank vehicle can have severe consequences, including environmental damage, injuries, and roadway closures.

For this reason, enforcement agencies closely examine:

• Tank integrity and design
• Required testing and inspection intervals
• Proper markings and placards
• Driver qualifications and training
• Documentation and emergency response information

When it comes to inspections, both the Federal Motor Carrier Safety Administration (FMCSA) and the Pipeline and Hazardous Materials Safety Administration (PHMSA) play key roles in regulating hazmat tank transportation.

Key Regulations Governing HazMat Tank Vehicles

Hazmat tank inspections are primarily governed by:

• 49 CFR Parts 171–180 for hazardous materials transportation
• 49 CFR Part 180 for tank inspection, testing, and maintenance
• 49 CFR Part 393 for vehicle safety requirements
• 49 CFR Part 172 for hazard communication, placarding, and shipping papers

Tank vehicles must meet all applicable DOT and UN standards before being placed into service.

Tank Inspection, Testing, and Certification Requirements

One of the most critical aspects of hazmat tank compliance is ensuring tanks are inspected and tested on schedule. Inspectors will verify:

• External visual inspections
• Internal visual inspections
• Pressure testing or leak testing, when required
• Thickness testing for corrosion or wear

Inspection intervals vary based on the tank specification and the material being hauled. Documentation proving that required inspections and tests were completed by qualified personnel must be available for review.

Violations are oftentimes caused by missing, expired, or incomplete tank test records. So, it’s important to make sure that all the information is in order before you hit the road. 

Vehicle Condition and Safety Equipment

During a hazmat tank DOT inspection, enforcement officers closely evaluate the overall condition of the vehicle, including:

• Tank shell, heads, piping, and valves
• Manholes, gaskets, and closures
• Emergency shutoff systems
• Hose assemblies and securement
• Braking systems, tires, lights, and suspension
• Spill containment and vapor recovery systems, if applicable

Any visible leaks, corrosion, damage, or improper repairs can result in immediate out-of-service orders.

Placarding, Marking, and Labeling

Hazmat tank vehicles must display the correct placards on all four sides of the vehicle when required by regulation. Inspectors will confirm:

• Placards match the material being transported
• Identification numbers are correct and legible
• Markings are durable and properly positioned
• Residue placards are displayed when tanks are not cleaned or purged

Incorrect or missing placards are among the most common hazmat violations during roadside inspections.

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Driver Qualifications and Training

Drivers operating hazmat tank vehicles must meet additional qualification standards, including:

• A valid CDL with both hazmat and tank endorsements
• Current medical certification
• Required hazmat training and recurrent training every three years
• Knowledge of emergency response procedures

Inspectors may also question drivers about the cargo they are hauling to confirm they understand the material and required safety measures.

Shipping Papers and Emergency Response Information

Accurate and accessible documentation is critical during a hazmat tank inspection. Required paperwork includes:

• Proper Shipping Name and UN or NA number
• Hazard class and packing group
• Quantity of material
• Emergency response information
• A 24-hour emergency contact number
• Shipper’s certification

Shipping papers must be within the driver's immediate reach when seated with the seat belt fastened.

Common HazMat Tank Inspection Violations

Some of the most frequent violations seen during hazmat tank inspections include:

• Expired or missing tank inspection and test records
• Leaking valves, fittings, or hoses
• Incorrect or missing placards
• Incomplete or inaccurate shipping papers
• Driver lacking proper endorsements or training
• Poor vehicle maintenance or unsecured equipment

Proactive inspections and preventative maintenance help reduce these risks.

Preparing for HazMat Tank DOT Inspections

Fleets can improve inspection outcomes by:

• Conducting regular tank and vehicle inspections
• Keeping inspection and test records organized and accessible
• Training drivers on hazmat regulations and inspection procedures
• Addressing maintenance issues immediately
• Partnering with experienced service providers familiar with hazmat compliance

Supporting HazMat Fleets in North Carolina

Hazmat tank DOT inspections require specialized knowledge, attention to detail, and strict adherence to federal regulations. Fleets operating in North Carolina must be prepared for both roadside inspections and facility audits.

Southeast Fleet Services supports hazmat tank operators with preventive maintenance, inspection-readiness, and compliance-focused services to help keep vehicles safe, legal, and on the road.