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How to Ship an Oversized Package

Oversized packages — those exceeding standard size or weight limits — face surcharges, special handling, and in some cases outright refusal from standard parcel carriers. Each carrier has different limits: USPS caps weight at 70 lbs and combined girth + length at 165 inches; UPS handles up to 150 lbs; FedEx Ground goes up to 150 lbs per package. Knowing these limits before printing your label prevents nasty surprise surcharges at the shipping counter. For packages exceeding all carrier limits, freight (LTL) is the right answer.

Step-by-step

1
Measure and weigh the package accurately
Measure: length (longest side), width, and height of the package as packed, including any pallet or crating. Calculate girth: 2×(width + height). Add length + girth for USPS comparison. For carriers, also calculate dimensional (DIM) weight: (L × W × H) / 139 for UPS/FedEx domestic. Carriers bill whichever is greater: actual weight or DIM weight.
2
Check USPS limits
USPS: max 70 lbs, max 130 inches combined length + girth (some Priority Mail services), max 165 inches for Retail Ground. Packages over 108 inches (length + girth) incur a non-machinable surcharge. Packages over these limits are refused at USPS counters.
3
Check UPS limits and surcharges
UPS: max 150 lbs, max 165 inches length + girth. Packages over 96 inches in length trigger a Large Package Surcharge (~$49 additional as of 2026). Packages over 150 lbs require UPS Freight (separate service). Residential deliveries incur an additional surcharge.
4
Check FedEx limits and surcharges
FedEx Ground/Home Delivery: max 150 lbs, max 165 inches length + girth. Oversize surcharges apply to packages over 96 inches in length or over 130 inches combined (currently ~$97 additional). Packages over 150 lbs are FedEx Freight territory.
5
For items over 150 lbs: use freight (LTL)
LTL (less-than-truckload) freight is for palletized shipments over 150 lbs. Providers: FreightQuote, GoShip, uShip, and direct accounts with UPS Freight or FedEx Freight. Freight shipments use a Bill of Lading (BOL), not a standard shipping label. Our tool does not generate freight BOLs.

Good to know

•DIM weight pricing is applied by UPS and FedEx — a large, lightweight box (like a lamp or bike) may cost more than you expect because they bill based on the space it takes, not just its weight.
•USPS does not charge dimensional weight — actual weight only. This makes USPS significantly cheaper for large, lightweight packages that fit within their 70 lb limit.
•Residential delivery surcharges from UPS and FedEx add $5–$7 per package on top of standard rates. Ship to a business address or a UPS/FedEx location for pickup to avoid this surcharge.