Shipping large, bulky, or heavy items comes with its own set of challenges—and cost traps. Whether it’s a piece of furniture, fitness equipment, or an unusually shaped product, mastering oversized shipping is essential for preserving margin and brand reputation. In this guide, you’ll learn:

• Carrier definitions & thresholds for oversized shipments

• Key cost drivers & how new 2025 rules amplify risk

• Strategies to mitigate oversize surcharges

• How Jay Group’s expertise helps brands simplify oversized logistics

What Counts as “Oversized shipping”?

There is no single universal definition—but carriers typically flag packages as oversized when one or more of these applies:

• Weight threshold exceeded (often 90 lbs, 150 lbs, or more)

• Combined length + girth threshold too large

• Longest side too long

• Irregular shape or low density (large but light)

Oversized Shipping Guide: Carrier Examples (2025)

• UPS: Any parcel whose length + girth > 130″ or whose length alone exceeds 96″ is considered a large package. Such packages may incur a Large Package Surcharge (LPS) or, for more extreme dimensions, be classified as Over Maximum Limits and routed as freight.

• FedEx: Similar thresholds apply; shipments exceeding 130″ combined or a longest side > 96″ often trigger Oversize Charges. For even larger parcels, FedEx Freight services may be required.

• USPS: For Parcel Select Oversize, length > 108″ and combined length + girth ≤ 130″ qualify for the oversized rate. Packages beyond those limits require custom pricing or alternate services.

• OnTrac: For western U.S. deliveries, OnTrac defines Large Package as any parcel with a longest side > 72″ or length + girth > 130″. Additional Handling applies if the longest side exceeds 48″, the second side 30″, weight > 50 lb, or combined dimensions exceed 105″. Large Package items have a minimum billable weight of 90 lb and a 40 lb minimum when Additional Handling applies.

⚠️ Because thresholds vary by carrier, shipment zone, and even time of year, always verify dimensional limits and surcharges before shipping.

Top Carriers for Oversized Shipments (2025)

Quick comparison for Oversized Shipping

⚠️ Key: L+G = length + (2×width) + (2×height).

What oversized shipping means in practice

• OnTrac can win on speed and cost inside its region, especially when your delivery ZIPs are concentrated in the Western US. Fewer “hub hops” and shorter lanes can offset national-carrier zone and handling stacks. But its strict AHS/Large Package thresholds (48″/105″ rules and minimum billable weights) mean you must measure and pack precisely.

• UPS & FedEx remain the baseline for national coverage. Their oversize triggers are similar (96″ longest side or 130″ L+G), but 2025 increases (and policy tweaks like FedEx’s cubic-volume criterion) can make large, light items expensive fast—especially after the round-up-each-inch measuring change.

• USPS is unique: once L+G >108″–≤130″, you pay the oversized price by zone regardless of weight; beyond 130″ L+G, it’s non-mailable. If you’re under a cubic foot, USPS often avoids DIM, which can help for certain compact/heavy items.

When to prefer local carries, like OnTrac for oversized shipping

• Destinations inside OnTrac’s footprint (dense West-coast demand) where UPS/FedEx LPS + zone stack up.

• Parcels near—but not over—OnTrac’s AHS/Large Package thresholds, where careful cartonization keeps you under 72″ length and ≤105″ L+G to avoid surcharges.

• Programs needing faster regional SLAs (e.g., next-day ground-like performance) without cross-country zones.

Guardrails: Build automated routing rules that (a) try OnTrac first for eligible ZIPs/dimensions, (b) fall back to UPS/FedEx when any OnTrac threshold is tripped, and (c) route to LTL/white-glove if any carrier hits Over-Max. Tie those rules to live dimension data so you don’t get surprised by minimum billable weights (OnTrac 40 lb for AHS, 90 lb for Large Package). ontrac.sirv.com

Jay Group’s take on oversized shipping

Jay Group offers reliable and sustainable third-party logistics (3PL) services with dual-coast fulfillment centers in the U.S., designed to provide fast, accurate, and scalable solutions for diverse product categories.  When it comes to oversized shipping we can assist with the following: 

• Pre-rate simulation: We model the same SKU/carton across UPS, FedEx, USPS, and OnTrac (regional) to pick the cheapest compliant path—before you ship.

• Dimension integrity: We use calibrated dimensioners and cartonization to keep you below 48″/72″ and 105″/130″ breakpoints where possible.

• Smart routing: Region-aware rules steer eligible orders to OnTrac, with auto-fallback to national carriers or LTL if limits are hit.

• Continuous audits: We watch 2025 surcharge updates, catch chargebacks, and refine packaging to avoid inch-rounding “gotchas.

Key Cost Drivers & 2025 Rule Impacts

Oversized charges can be surprisingly steep. The main cost drivers:

1. DIM Weight / Low density items
   Oversized packages often have a lot of empty space—so carriers use dimensional weight to price more fairly.
   In 2025, the impact intensifies: FedEx and UPS now round every fractional inch up (e.g. 11.1″ → 12″) before computing volume, increasing billed weight for many oversized parcels.

2. Surcharges & Handling Fees
   Oversize or “Large Package” surcharges can stack with other factors (residential delivery, liftgate, inside delivery). Some carriers now have peak oversize surcharges or escalators.
   UPS’s 2025 rate updates also realigned zones and increased large/handling fees, making oversize lanes even more expensive.

3. Over Maximum / Freight Reclassification
   If your package exceeds a carrier’s “Over Maximum” limits by weight or dimension, it may be forced onto freight services—which often have different rules, transit times, and costs.

4. Zone & Distance Exposure
   Oversized items farther from fulfillment centers incur both high zone costs and compounding DIM surcharges.

Strategies to Reduce Oversized Costs

Here’s how brands can defend margins even on big shipments:

Right-size & Optimize Packaging

• Use custom crates, adjustable cartons, or modular packaging to minimize space.

• Eliminate extra padding or voids that inflate volume.

• Test multiple box sizes: sometimes two smaller boxes cost less than one huge one under surcharges.

Pre-Measure & Use Measurement Tech

• Use devices like Cubiscan or dimensioning stations to capture precise dimensions.

• Avoid rounding “down”; use the same rounding logic carriers do (post-2025, always round up every inch).

• Maintain reliable dimension history so you can audit or dispute charges.

Zone & Node Optimization

• Ship oversized items from the node closest to the customer to reduce zone distance impact.

• Use Jay Group’s East/West DC network to mitigate long cross-country oversize costs.

Leverage Freight & Hybrid Models

• If a package exceeds parcel limits (weight or size), shift to LTL freight or full truckload.

• For very heavy or bulky SKUs, consider white-glove or curbside freight for delivery to doorstep.

Negotiate Carrier Terms & Accessorial Caps

• Use data to push back on oversize surcharges or gain caps / cushions.

• Negotiate volume guarantees, surcharge caps, or discounted oversize accessorial based on your volume profile.

Monitor & Audit Shipping Bills

• Use analytics to flag oversize charge spikes, dimension drift, or zone reclassifications.

• Dispute systematic overcharges using validated dimension history.

• Re-run shipping models on returned or canceled oversize shipments.

Jay Group’s Oversized Shipping Advantage

At Jay Group, oversized shipping isn’t a burden—it’s part of our specialization. Here’s how we add value:

• Oversize Audit & Cost Forecasting: Before shipping, we simulate billing under various carrier rules to flag high-risk shipments.

• Dimensional Intelligence & Automation: Our systems capture exact dimensions, feed that to smart routing, and eliminate manual error.

• Customized Packaging Strategy: We design and test crate, pallet, or modular packaging libraries tailored to your SKUs.

• Flexible Node Routing: Our dual-coast DC locations allow us to route oversized orders from the least costly node.

• Freight & First/Last Mile Logistics: We seamlessly blend freight, parcel, and white-glove delivery to get oversized items to customers efficiently.

• Rate Negotiation Power: Using aggregated oversize data across clients, we negotiate better surcharges, accessorial limits, or custom pricing with carriers.

• Ongoing Monitoring & Audits: We continuously track dimension drift, oversize billing trends, and carrier rule changes to safeguard your shipping spend.

Final Thoughts & Next Steps

Oversized shipping is complex, but it doesn’t have to erode your margins or frustrate your operations. With the right strategy, tools, and partner (like Jay Group), you can turn oversized logistics into a competitive advantage. If you’d like us to run an oversize cost audit on your SKUs or design crate solutions for your biggest products, reach out. We’ll show you exactly where you’re leaking—and how to stop it.