Oversize Package Fees: How UPS and FedEx Charge and How to Avoid Them
A single large box can cost more to ship than you expect. Sometimes much more.
If you ship big or bulky items with UPS or FedEx, you have probably seen oversize package fees on your invoice. These charges can add hundreds of dollars to a single package. And because they are buried in long invoices, many businesses don’t notice them until the costs have piled up.
Quick answer: UPS and FedEx add an oversize fee when a package is longer than 96 inches, or when its length plus girth is more than 130 inches. UPS also checks total box volume. These packages are billed as if they weigh at least 90 lbs, and the fee alone can be more than $200 per package. The easiest way to avoid it is to use smaller, better-fitted boxes.
This guide explains how the UPS oversize package fee and the FedEx oversize package fee work, how to spot them on your invoice, and what you can do to reduce them.
What are oversize package fees?
Oversize package fees are extra charges that carriers add when a package is too big to move easily through their normal network. Large boxes take up more space in trucks, need more handling, and often can’t run on standard conveyor belts.
These fees are one type of parcel shipping surcharges. They sit alongside other carrier accessorial fees, such as residential delivery fees, address correction fees and fuel surcharges. They are added on top of your normal shipping rate.
UPS calls this charge the Large Package Surcharge. FedEx calls it the Oversize Charge. The names differ, but the idea is the same.
When does UPS charge an oversize package fee?
UPS adds its Large Package Surcharge when a package meets any one of these conditions:
The longest side is more than 96 inches
Length plus girth is more than 130 inches
The total volume is more than 17,280 cubic inches (this rule took effect in January 2026)
The actual weight is more than 110 lbs
Packages that get this surcharge are also billed at a minimum of 90 lbs, even if they weigh much less.
As of December 2025, the domestic fee ranges from about $219 to $286 per package for business addresses, depending on the shipping zone. Residential deliveries cost more, from about $254 to $331.
UPS also has a hard upper limit. Packages over 150 lbs, longer than 108 inches, or more than 165 inches in length plus girth are not normally accepted. If one gets into the network anyway, UPS can charge a flat $1,875 fee.
When does FedEx charge an oversize package fee?
FedEx uses very similar rules. Its Oversize Charge applies when a package is:
More than 96 inches long, or
More than 130 inches in length plus girth
Like UPS, FedEx bills these packages at a minimum of 90 lbs. The charge is based on whichever is higher: the real weight or the dimensional weight.
FedEx fee amounts are listed in its yearly Service Guide. They are in the same general range as UPS, often well over $200 per package. Both carriers raise their rates every year, so it’s worth checking the current guide.
What is “length plus girth” and how do you measure it?
This is the measurement that catches most businesses off guard.
Length is the longest side of the box.
Girth is the distance around the box at its thickest point. To get it, add the two shorter sides together and multiply by two.
Length plus girth is those two numbers added together.
Example: A box measures 50 x 30 x 20 inches.
Length = 50
Girth = (30 + 20) x 2 = 100
Length plus girth = 150 inches
That is over the 130-inch limit, so this box would get an oversize fee. Even if it weighs only 25 lbs, it would also be billed as 90 lbs.
What is the difference between oversize fees and additional handling fees?
These are two separate charges, and they are often confused.
An additional handling fee is a smaller charge for packages that are large or awkward, but not big enough to count as oversize. UPS applies it when, for example:
The longest side is more than 48 inches
The second-longest side is more than 30 inches
Length plus girth is more than 105 inches
The package weighs more than 50 lbs
For UPS, this fee usually runs about $30 to $59 per package, depending on the reason and the zone. FedEx has a similar Additional Handling charge.
A package can’t get both charges at once. If it qualifies as oversize, the larger oversize fee replaces the additional handling fee. That’s why one size can make a big difference to your bill.
How much can oversized shipping charges really cost?
Here is a simple example using made-up numbers.
A company ships the 50 x 30 x 20 box from above. It gets the oversize fee, about $240 in a mid-range zone, plus 90 lbs of billable weight.
Now the company switches to a better-fitted box of 46 x 22 x 14 inches. Length plus girth drops to 118 inches, and the volume is about 14,170 cubic inches. The box is now under both oversize limits.
It may still get an additional handling fee of around $33. But that is far less than the oversize fee. And the 90 lb minimum no longer applies.
If the company ships 20 of these boxes a week, the savings can easily add up to tens of thousands of dollars a year. Nothing changed except the box.
Who is most affected by oversized shipping charges?
Manufacturers are often hit hardest. They ship machine parts, equipment, panels and other long or heavy items. One product line in a box that’s slightly too big can create oversize fees on every order.
Suppliers and distributors see it too. Bulky items like furniture parts, display units or mixed orders packed into one large box can easily cross the limits. Residential deliveries make it worse, since UPS charges more for oversize packages going to homes.
How can you avoid oversize package fees?
You can’t always avoid them. Some products are simply large. But you can often reduce how often they appear.
Measure your top products. Know the exact length plus girth for your most-shipped items.
Right-size your boxes. Even 1 or 2 inches can move a package under the limit.
Cut down extra packing space. Too much padding makes boxes bigger than they need to be.
Split large orders. Two smaller boxes can cost less than one oversize box.
Ship flat or knocked down when possible. Items that can be taken apart often fit in smaller boxes.
Consider freight for very large items. For heavy or huge shipments, LTL freight may be cheaper than parcel.
Review your carrier contract. Some contracts include discounts on certain surcharges. Check what yours says before renewal.
How do you find oversize fees on your invoice?
Oversize fees are usually listed as a separate line under each shipment. On UPS invoices, look for “Large Package Surcharge.” On FedEx invoices, look for “Oversize Charge.”
The tricky part is that carriers measure packages with scanners in their hubs. If their measurement is bigger than what you entered, you may see a fee you didn’t expect, along with a shipping charge adjustment.
To stay on top of this, check your invoices for:
How many packages got oversize or additional handling fees each week
Which products or box sizes cause them most often
Any cases where the carrier’s measurement differs from yours
How does Franklin Parcel help with oversize package fees?
Franklin Parcel helps you see exactly where your oversize package fees and other carrier accessorial fees are coming from.
It connects to your UPS and FedEx billing data and shows which shipments, products and box sizes are getting oversize or additional handling charges. You can see how often these fees appear, how much they cost each week, and where the carrier’s measurements differ from yours.
With that information, your team can decide which boxes to change, which items to ship differently, and which surcharges to raise in your next contract talks.
We give you a clear view of what you are being charged and why, so you can make better shipping decisions.
Frequently asked questions
Q: Do UPS and FedEx oversize rules change every year?
A: Yes. Both carriers usually update fee amounts each year and sometimes change the size rules too. UPS added new volume and weight rules in January 2026.
Q: Can oversize package fees be negotiated?
A: Sometimes. Discounts on surcharges and accessorial fees can be part of a carrier contract, depending on your volume and shipping profile.
Q: Does dimensional weight affect oversize packages?
A: Yes. Oversize packages are billed at the higher of their real weight, their dimensional weight, or the 90 lb minimum.
Author: Nicolas Telesca
Nicolas Telesca has more than 15 years of experience in logistics and parcel transportation. He is Co-Founder and Chief Analyst at Franklin Parcel and works closely with large shipping operations at a national 3PL, specializing in carrier contracts, shipping analytics, and cost visibility across UPS and FedEx networks.
Comments