Additional Handling
Also known as: Additional Handling Surcharge, AHS, Special Handling Fee
Definition
Additional handling surcharges are extra fees carriers charge for packages that don’t fit standard processing and require special treatment. These packages may slow down automated sorting systems or need manual handling.
Triggers for Additional Handling
Size-Based Triggers
UPS/FedEx typical thresholds:
- Longest side over 48 inches
- Second-longest side over 30 inches
- Length + girth over 105 inches
Weight-Based Triggers
- Packages over 50 lbs (UPS)
- Packages over 50 lbs (FedEx)
- Actual or dimensional weight
Packaging Triggers
- Not in corrugated cardboard box
- Metal or wood containers
- Cylindrical packages (tubes, drums)
- Soft packaging (bags, poly mailers) for heavy items
- Items not fully enclosed
- Palletized shipments sent as parcels
Additional Handling Fee Amounts
| Carrier | Package Criteria | Approximate Fee |
|---|---|---|
| UPS | Dimensions exceeded | $15-$18 |
| UPS | Weight exceeded | $15-$18 |
| UPS | Packaging type | $15-$18 |
| FedEx | Dimensions exceeded | $15-$18 |
| FedEx | Weight exceeded | $15-$18 |
| FedEx | Packaging type | $15-$18 |
Note: Fees increase annually. Only one AHS charged per package even if multiple criteria met.
Additional Handling vs. Oversize
| Charge | Criteria | Typical Fee |
|---|---|---|
| Additional Handling | Exceeds AH thresholds | $15-$18 |
| Oversize | Exceeds oversize limits | $90-$110 |
| Large Package | Length + girth > 130" | $100-$115 |
Note: Oversize is more severe than additional handling.
Common Products That Trigger AHS
- Large electronics (TVs, monitors)
- Furniture components
- Automotive parts
- Sports equipment (skis, golf clubs)
- Musical instruments
- Industrial supplies
- Bagged products over 50 lbs
- Artwork and frames
- Rolled goods (carpets, posters in tubes)
How to Avoid Additional Handling Fees
Packaging Strategies
- Use proper boxes - Corrugated cardboard, not bags for heavy items
- Ship disassembled - Break down to smaller boxes
- Multi-box shipments - Split heavy items
- Avoid tubes - Use rectangular boxes when possible
Product Changes
- Redesign packaging - Fit standard size constraints
- Lighter materials - Reduce weight below 50 lbs
- Different box dimensions - Stay under thresholds
Carrier Alternatives
- Freight/LTL - For very large items
- Specialized carriers - Oversized item specialists
- Regional carriers - May have different thresholds
- USPS - Different surcharge structure
Calculating Total Shipping Cost
Example calculation:
| Component | Cost |
|---|---|
| Base rate (Zone 5, 40 lbs) | $35.00 |
| Fuel surcharge (8%) | $2.80 |
| Additional handling (52" length) | $15.00 |
| Residential surcharge | $4.50 |
| Total | $57.30 |
The additional handling fee adds significantly to the base rate.
Business Considerations
For e-commerce sellers:
- Build AHS into product prices
- Offer accurate shipping estimates
- Consider product packaging redesign
- May need special shipping tiers
For high-volume shippers:
- Negotiate AHS caps in contracts
- Audit invoices for incorrect charges
- Track products triggering AHS
- Evaluate packaging alternatives
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