Is my shipment oversize? A guide to large package shipping size limits and options.
When it comes to large package shipping, understanding the definitions of "oversize," "large" and "heavy" packages is crucial for avoiding unexpected surcharges. If your business deals with bulky or heavier packages, you've probably seen additional fees on your invoices related to package size and weight. However, the terminology can be confusing, and understanding these terms is key to effectively managing shipping costs.
Carriers like UPS® define precise parameters for what qualifies as an oversize or large package delivery and knowing these parameters can help you minimize unnecessary costs or avoid them altogether. This guide dives into the three primary categories of large package shipping, the measurements that define them, potential surcharges and tips for reducing costs!
Additional Handling Charge
Once packages exceed certain dimensions or weight, they incur an additional handling surcharge. For UPS large parcel shipping within the U.S., packages will be subject to this charge if they meet any of the following criteria:
- 48 inches or more on the longest side (length)
- 30 inches or more on the second-longest side (width)
- More than 105 inches in combined length plus girth [(2 x width) + (2 x height)]
- More than 50 lbs.
If any one of these measurements or weight limits is exceeded, your package will incur a handling charge. The good news is that this charge is only applied once per package, meaning if your shipment exceeds multiple limits, you'll be charged the highest of the surcharges.
Additional handling fee breakdown
So, what does "additional handling" mean in terms of cost? The exact surcharge differs by shipping zone, and the fee is higher if your package is above the 50-lb. weight limit than if it exceeds the other dimensional limits. And for packages assessed the fee due to length, width or length plus girth, the minimum billable weight is 40 lbs. even if it's lighter than that. Since fees are updated periodically, you should check current UPS rates for a dollar amount.
Large Package Surcharge
If your package exceeds certain size limits, it will incur a large package surcharge instead of the additional handling charge mentioned above. For UPS domestic parcel shipping, this applies to packages that:
- Exceed 96 inches in length
- Exceed 130 inches in combined length plus girth
This surcharge is typically higher when it is applied due to length plus girth, particularly for residential destinations. Additionally, large packages are subject to a minimum billable weight of 90 lbs., which means if your package weighs less than 90 lbs., you'll still be charged at the 90-lb. rate.
Like other surcharges, the exact fee for large packages will vary depending on the shipping zone. Always check UPS guidelines for the most current rate information.
Oversize Packages: Know the Limitations
The limits for oversize package shipping are more stringent. If your package exceeds any of the following measurements, it will be classified as oversized, and you may be required to use freight shipping instead:
- 150 lbs. or more
- 108 inches in length or more
- 165 inches or more in combined length plus girth
What happens if your package exceeds these limits?
When a package is too large for standard parcel shipping but there is still an attempt to ship it, UPS may process the shipment, but they reserve the right to return the package to the sender at their own expense. Additionally, packages that exceed these size or weight thresholds are subject to an over maximum limits charge, which for 2025 is $1,325 per package.
To avoid these hefty fees, it's important to measure your packages carefully before shipping and ensure they stay within acceptable limits.
Small Package Size Breakdown
If your packages exceed any of the following measurements, here is what you can expect:
| Weight | Length (longest side) | Width (2nd longest side) | Combined length & girth (length + [2x width + 2x height]) | Here's what it means:*** |
| 50 lbs.* | 48 inches | 30 inches | 105 inches | Additional Handling fee applies |
| n/a | 96 inches** | n/a | 130 inches | Large Package Surcharge applies |
| 150 lbs. | n/a | 108 inches | 165 inches | Package is oversize (too big for parcel shipping) |
* 55 lbs. for international.
** Doesn't apply to international packages.
*** Fees vary by origin/destination shipping zones, weight vs. size, and domestic vs. international.
International Shipments: Size and Weight Considerations
When shipping internationally with UPS, there are similar size and weight limitations for parcel shipping. However, there are some notable differences:
- Additional handling fee: For international shipments, the fee applies to packages weighing 55 lbs. or more, as opposed to the 50-lb. limit for domestic shipments.
- Large package surcharge: International packages are only assessed based on combined length plus girth, not the length alone.
- Oversize package limits: The size and weight thresholds for oversized package shipping remain the same for both domestic and international shipments. However, the over maximum limits fee is typically higher for international shipments.
Always double-check UPS guidelines for international shipments to avoid unexpected charges and to ensure your parcel delivery is smooth and cost-effective.
How Dimensional Weight Affects Large and Oversize Shipments
Another way that larger boxes can get a higher rate is by falling under dimensional (or DIM) weight pricing. In order to encourage customers to opt for right-sized packaging,which optimizes cargo space and allows UPS to fit more packages in a vehicle, packages that are large but not heavy are priced differently. Carriers devise their own system to determine this, and a package's billable weight will be the higher of either actual or dimensional weight.
To determine if your package will be billed by its dimensional weight, check the carrier's rate guide. Typically, you'll multiply length x width x height and divide by a specific number to get the dimensional weight.
If you're wondering how DIM weight applies to the large and oversize rules — it doesn't. Those surcharges and categories are based on real weight and/or the dimensions of the package, not the DIM weight calculation.
Tips for Shipping Large or Oversize Packages
If your package falls into the large package delivery or oversized package categories, here are some ways to avoid or minimize surcharges:
- Right-size your packaging: If the box itself is the issue, consider repacking your items into a smaller box. Just be sure not to exceed the weight limits or compromise on padding to protect your items.
- Divide contents into multiple packages: If your shipment is oversized, breaking it down into smaller packages may help you avoid the additional handling or large package surcharges.
- Explore special rates for multiple shipments: By splitting a larger shipment into multiple smaller packages, you may qualify for UPS Hundredweight Service® or other cost-saving programs.
- Consider freight shipping: If no other options work, freight services like less-than-truckload (LTL) or full truckload (FTL) may be more cost-effective for your oversized package delivery. A third-party logistics provider like Unishippers can help you choose the right freight option.
Get Help With Your Large Package Shipping
If you need assistance navigating the complexities of large package shipping, oversized package delivery or finding the best way to manage surcharges, Unishippers' logistics experts are here to help. We can assist you with everything from choosing the best shipping method to optimizing your packaging to avoid unnecessary fees.
At Unishippers, we pride ourselves on helping SMBs like yours create custom shipping solutions and optimize their logistics processes. As a 3PL provider of choice for 113,000+ shippers across the nation, we offer top solutions and support to help your business thrive. And as part of the nation's largest non-retail authorized reseller of UPS, Unishippers gives you access to affordable rates and service options to meet your unique business shipping needs!
See how Unishippers can help you optimize your shipping for cost savings and better logistics outcomes. If you are ready to talk to an expert about our parcel solutions, reach out for a free consultation today!
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