Oversize Package
Also known as: Oversized Package, Large Package, Non-Standard Package
Definition
An oversize package is a shipment that exceeds a carrier’s standard parcel dimensions, triggering significant surcharges or requiring alternative shipping methods like freight. Understanding size limits helps you avoid unexpected fees and choose the right shipping method.
Carrier Size Limits
UPS
| Classification | Criteria | Surcharge |
|---|---|---|
| Large Package | Length + girth > 130" | ~$110 |
| Maximum size | Length + girth ≤ 165" | Ship as parcel |
| Over maximum | Length + girth > 165" | Requires freight |
Additional limits:
- Maximum length: 108 inches
- Maximum weight: 150 lbs
FedEx
| Classification | Criteria | Surcharge |
|---|---|---|
| Oversize | Length + girth > 130" | ~$115 |
| Maximum size | Length + girth ≤ 165" | Ship as parcel |
| Over maximum | Length + girth > 165" | Requires freight |
Additional limits:
- Maximum length: 108 inches
- Maximum weight: 150 lbs
USPS
| Service | Maximum Size |
|---|---|
| Priority Mail | 108" length, 130" L+girth |
| Ground Advantage | 130" L+girth |
| First-Class | 22" length |
Maximum weight: 70 lbs
Calculating Length + Girth
Formula: Length + Girth = Length + (2 × Width) + (2 × Height)
Example: Box: 40" × 20" × 15"
- Length = 40"
- Girth = (2 × 20) + (2 × 15) = 70"
- Length + Girth = 110" (under 130", no large package fee)
Example triggering surcharge: Box: 50" × 25" × 20"
- Length = 50"
- Girth = (2 × 25) + (2 × 20) = 90"
- Length + Girth = 140" (over 130", surcharge applies)
Oversize vs. Additional Handling
| Fee Type | Trigger | Typical Cost |
|---|---|---|
| Additional Handling | Longest side > 48" | $15-$18 |
| Additional Handling | Second side > 30" | $15-$18 |
| Large Package/Oversize | L+G > 130" | $100-$115 |
Note: Both fees can apply to the same package.
Strategies for Oversize Items
Reduce Dimensions
- Ship disassembled
- Use flat-pack design
- Remove unnecessary packaging
- Compress where possible
Split Into Multiple Packages
- Separate heavy from bulky
- Multiple boxes vs. one oversize
- Calculate which is cheaper
Use Freight Instead
- Often cheaper for truly large items
- LTL for palletized goods
- Better handling for heavy items
- Compare parcel + surcharges vs. freight
Specialized Carriers
- Freight carriers (Estes, XPO)
- White glove delivery services
- Specialty item shippers
- Regional carriers with different limits
Cost Comparison Example
Shipping a 45" × 30" × 25" box, 60 lbs
| Method | Estimated Cost |
|---|---|
| UPS Ground + surcharges | $85 + $18 AHS + $110 Large = ~$213 |
| FedEx Ground + surcharges | Similar to UPS |
| LTL Freight | ~$150-$200 |
| Regional carrier | ~$120-$160 |
For large items, freight is often more economical.
Industries Commonly Affected
- Furniture: Couches, tables, mattresses
- Fitness: Treadmills, weight benches
- Electronics: Large TVs, appliances
- Automotive: Bumpers, hoods, exhausts
- Sports: Kayaks, surfboards, bikes
- Art: Large canvases, sculptures
Shipping Oversize: Best Practices
- Measure accurately - Include packaging dimensions
- Compare all options - Parcel, freight, specialty
- Use DIM weight calculators - Know billable weight
- Consider delivery needs - Lift gate, inside delivery
- Build costs into pricing - Don’t absorb surprises
- Package securely - Large items need extra protection
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