Shipping heavy items can be a challenge, especially with varying weight thresholds and potential extra fees lurking around every corner. To sidestep steep rates, it’s important to select the ideal carrier and service and to familiarize yourself with the specifics of heavy-package shipping.
With over 12 years of specialized experience in handling and shipping heavy packages, we know what drives up carrier fees. We also know how to find affordable alternatives. In this guide, we’ll share the cheapest options for shipping various heavy packages across different distances.
Granted, no two people have the same definition of a heavy package. Plus, myriad factors, such as carrier restrictions and dimensions, impact each shipment. However, the following examples of commonly shipped heavy items will provide insights into typical variables and costs. You can then use these insights to inform your own heavy shipments and potentially cut costs.
TL;DR:
Key takeaways
The cheapest way to ship most heavy packages is through UPS Ground, booked at discounted rates via platforms like PirateShip.
For small and dense heavy items (e.g., kettlebells or dumbbells), the cheapest option is flat-rate shipping through UPS Simple Rate, provided the package meets the program’s sizing guidelines.
Discount platforms don’t typically guarantee arrival times, so you might not get refunded for delays.
The greater the shipping distance, the more you’ll save by shipping a heavy item at flat rates.
For large packages, like picture frames, the shipping cost might be calculated based on the dimensional weight instead of the actual weight. So, the dimensions of your package are also critical for carrier-fee analysis.
What you’ll learn
The cheapest way to ship heavy packages depending on size, distance, and package type.
Real-world prices for shipping different heavy items, compared across different distances and carriers.
Key factors that affect shipping fees.
Four money-saving strategies that might lower your transport costs.
PRO TIP: Running an ecommerce business that ships heavy products? Red Stag Fulfillment offers specialized services for omnichannel brands with large and heavy items. Learn more about our big, heavy, and bulky 3PL services today.
What is the cheapest way to ship a heavy package?
The cheapest way to ship a heavy package is UPS Ground booked through the PirateShip platform, which has significant volume-based discounts with the carriers.
On the other hand, if the heavy package is small enough to qualify for flat-rate shipping*, UPS Simple Rate will be the cheapest transport option.
If you want to avoid shipping platforms, FedEx Ground and UPS Ground will be the cheapest options for sending heavy items at standard rates, depending on distance and package type.
Finally, some shipping services are not available through discount platforms. For example, you can only schedule a UPS Saturday delivery to your business through the carrier’s website. That option doesn’t exist on PirateShip.
Moreover, PirateShip does not guarantee arrival times, which means there are no refunds for delays.
NOTE: Flat-rate shipping is a pricing model that applies a single, fixed fee across a range of shipping variables like distance and weight. With most flat-rate programs, shipping a package coast-to-coast and down the street will cost the same, provided the item doesn’t exceed the size and weight limits (50 lbs for UPS and FedEx and 70 lbs for USPS). Therein lies the key constraint for heavy packages; they’re usually too large for flat-rate shipping.
To see if your package qualifies for flat rates, visit the following dedicated pages on carrier websites:
Shipping heavy and large packages: Carrier cost comparison
The tables in this section compare the shipping costs by carrier and distance for three heavy packages. The bolded numbers in the tables emphasize the cheapest transport options for each item, distance, and shipping speed.
To get the cost estimates in the tables, we used the following assumed objects and distances:
A compact, heavy item is a cast-iron calibration weight. It measures 7.9″ x 5″ x 6.6″ and weighs 50 lbs, which is within the volume, size, and weight limits for flat-rate shipping with all major carriers.
A bulky and heavy object is a picture frame. It weighs 50 lbs and measures 50″ x 50″ x 5″.
The large, heavy, and dense package includes a horizontal shaft engine. The package weighs 110 lbs and measures 21″ x 20″ x 22″.
Local shipping is within the LA area (Zone* 2, 0 to 150 miles).
Interstate shipping is from LA to Oklahoma City (Zone 6, 1,001 to 1,400 miles).
NOTE: Shipping zones are areas that carriers use to factor in distance when determining transport costs. A shipping zone is defined by the ZIP codes of the package’s origin and arrival points. Learn more in our guide on shipping zones.
Shipping costs for a 50-lb cast-iron calibration weight
The cast-iron weight is small enough to qualify for flat-rate shipping with all major carriers. It fits the large flat-rate boxes in FedEx and USPS programs and qualifies as a medium-sized package in UPS’ Simple Rate classification.
The first two tables show the flat and regular shipping rates for the cast-iron weight.
| Carrier | Local shipping (Zone 2, 0 to 150 miles) | Interstate shipping (Zone 6, 1,001 to 1,400 miles) | ||
|---|---|---|---|---|
| Cheapest service (typically ground) | Express service (typically next-day air) | Cheapest service (typically ground) | Express service (typically next-day air) | |
| FedEx One Rate (FedEx Express Saver and FedEx Priority Overnight) | $25.50 | $69.75 | $25.50 | $123.15 |
| UPS Simple Rate (UPS Ground and UPS Next Day Air Saver) | $20.40 | $60.25 | $20.40 | $60.25 |
| USPS flat-rate pricing (USPS Priority Mail) | $26.30 | * | $26.30 | * |
| PirateShip | $22.98 (through UPS Ground Saver) | $54.68 (through UPS Next Day Air Saver) | $52.09 (through UPS Ground Saver) | $194.10 (through UPS Next Day Air Saver) |
Regular (calculated) shipping costs for the 50-lb cast-iron weight
The table below shows the weight’s shipping costs estimated using the carrier calculators instead of flat rates.
| Carrier | Local shipping (Zone 2, 0 to 150 miles) | Interstate shipping (Zone 6, 1,001 to 1,400 miles) | ||
|---|---|---|---|---|
| Cheapest service (typically ground) | Express service (typically next-day air) | Cheapest service (typically ground) | Express service (typically next-day air) | |
| FedEx (FedEx Ground or Home Delivery vs. FedEx Priority Overnight) |
$39.55 | $216.65 | $99.12 | $576.04 |
| UPS (UPS Ground vs. UPS Next Day Air Saver) |
$42.08 | $166.33 | $104.94 | $548.48 |
| USPS (USPS Ground Advantage vs. USPS Priority Mail Express 1-Day) |
$46.15 | $162.95 | $107.85 | $382.85 |
| PirateShip | $22.98 (through UPS Ground Saver) |
$54.68 (through UPS Next Day Air Saver) |
$52.09 (through UPS Ground Saver) |
$194.10 (through UPS Next Day Air Saver) |
Carrier shipping costs for a 50-lb picture frame
PirateShip is the cheapest option across the board, and the frame’s 50″ x 50″ x 5″ dimensions are too large for USPS shipping.
| Carrier | Local shipping (Zone 2, 0 to 150 miles) | Interstate shipping (Zone 6, 1,001 to 1,400 miles) | ||
|---|---|---|---|---|
| Cheapest service (typically ground) | Express service (typically next-day air) | Cheapest service (typically ground) | Express service (typically next-day air) | |
| FedEx (FedEx Ground or Home Delivery vs. FedEx Priority Overnight) |
$333.54 | $580.96 | $380.69 | $1,259.61 |
| UPS (UPS Ground vs. UPS Next Day Air Saver) |
$305.81 | $540.83 | $448.63 | $1,272.71 |
| USPS | Too large to ship | Too large to ship | Too large to ship | Too large to ship |
| PirateShip | $135.73 (through UPS Ground) |
$176.72 (through UPS Next Day Air Saver) |
$159.91 (through UPS Ground) |
$412.75 (through UPS Next Day Air Saver) |
Carrier shipping costs for a 110-lb engine
The engine exceeds USPS weight limits, and once again, PirateShip is the cheapest option.
| Carrier | Local shipping (Zone 2, 0 to 150 miles) | Interstate shipping (Zone 6, 1,001 to 1,400 miles) | ||
|---|---|---|---|---|
| Cheapest service (typically ground) | Express service (typically next-day air) | Cheapest service (typically ground) | Express service (typically next-day air) | |
| FedEx (FedEx Ground or Home Delivery vs. FedEx Priority Overnight) |
$172.02 | $435.18 | $214.35 | $1,214.34 |
| UPS (UPS Ground vs. UPS Next Day Air Saver) |
$182.86 | $419.60 | $228.73 | $1,171.85 |
| USPS | Too heavy to ship | Too heavy to ship | Too heavy to ship | Too heavy to ship |
| PirateShip | $88.27 (through UPS Ground) |
$176.72 (through UPS Next Day Air Saver) |
$107.28 (through UPS Ground) |
$413.48 (through UPS Next Day Air Saver) |
*NOTE: USPS’ weight limit for parcel shipping is 70 lbs, which is the lowest among the major carriers. UPS and FedEx’s weight limit is 150 lbs. We’ll break down the size limits in a dedicated section below.
Key factors affecting the shipping costs of heavy packages
The package weight is only one of the critical factors that affect shipping rates. Other key variables in the shipping-cost equation are listed below.
Shipping distance
The greater the distance between the shipment’s origin and destination point, the greater the cost.
Flat-rate shipping is the exception to that rule, but most heavy packages will be too big to qualify for flat rates. (See “Regular vs. flat-rate shipping of heavy packages” below.)
To illustrate how shipping distance affects transport costs, let’s consider a 50-lb kettlebell. The table below shows the estimated fees for shipping the kettlebell through FedEx standard shipping (Ground or Home Delivery) and FedEx First Overnight. The table also compares the shipping costs for three distances: local, medium interstate, and coast-to-coast.
| Distances | FedEx standard shipping (Ground or Home Delivery) | FedEx First Overnight |
|---|---|---|
| Within LA (Zone 2, 0-150 miles) | $39.55 | $234.20 |
| LA to Denver (Zone 5, 601-1,000) | $78.37 | $580.50 |
| LA to New York (Zone 8, 1,801 or more) | $134.41 | $681.29 |
BOTTOM LINE: The cost difference between shipping a heavy package locally and across the country might be 300-400%.
Size limits for shipping large packages
Carriers might bill for shipping based on the actual or dimensional weight. If you’re shipping a bulky, heavy package, like a picture frame, the dimensional weight will likely exceed the actual numbers on the scale.
However, shipping fees will likely be based on the actual weight if you’re shipping dense, heavy items, like weights or engines. In this scenario, the package size is only a factor if it exceeds the limits for standard shipping shown in the table below.
| Size and weight limits for shipping a heavy package | |||
|---|---|---|---|
| UPS | FedEx | USPS | |
| Length and girth combined (inches) | 165 | 165 (130 for Express) | 108 (130 for Retail Ground, charged as oversized) |
| Length (inches) | 108 | 108 | * |
| Weight (pounds) | 150 | 150 | 70 |
NOTE: When a package exceeds these limits, it will be shipped as freight. That means it will be separated from the smaller packages and secured to a pallet or in a crate. Freight transport typically costs more than standard parcel shipping. See our guide on the differences between parcel shipping and freight to learn more.
Dimensional vs. actual weight of a package
Dimensional weight is a pricing concept that allows carriers to charge for shipping based on package size instead of weight. For example, if you’re shipping a picture frame that measures 50″ x 50″ x 5″ and weighs 50 lbs, you’ll be charged based on the dimensional weight, which is 76 lbs or 90 lbs, depending on the carrier.
To see which weight applies to your package, use our dimensional weight calculator.
Shipping service–mode and speed
Ground shipping is by far the cheapest way to transport heavy items.
To illustrate the difference, let’s assume you’re shipping a 50-lb engine directly through one of the major carriers. Ground shipping for this transport would cost approximately $200-$230, while a next-day air shipment would cost $1,150-$1,250.
That is a five-fold difference.
Another example would be shipping a 110-lb engine at discounted rates through PirateShip. If you book through the PirateShip platform, the cost of shipping the engine through UPS Ground and UPS Next Day Air Saver would be $107.28 and $413.48, respectively.
That is a four-fold difference.
BOTTOM LINE: Expedited shipping costs four to five times more than standard ground shipping. Expedited services typically use air transport and will get the engine to its destination in one day, while ground shipping might take two to three days for longer distances.
Regular vs. flat-rate shipping of heavy packages
Flat-rate shipping should be simple and predictable. That’s the whole point of it.
In its basic form, it should work like this:
01
You choose a box.
02
The carrier sends it to you.
03
You pack anything you want into the box, provided the item(s) are within the weight limits.
04
You choose a transport speed/service.
05
The carrier ships it at a fixed rate to any part of the continental United States.
In reality, carrier policies for flat-rate transport aren’t so simple. There are unexpected variables–from box shapes and capacities to distance classes.
In this section, we’ll examine the unique aspects of each carrier’s flat-rate policy and highlight what it means for shipping heavy packages.
USPS flat-rate shipping
USPS only has one flat-rate option to ship a heavy item like the 50-lb cast-iron weight we used for the cost estimates. They can transport it through Priority Mail in a Medium or Large Flat-Rate Box. To allow room for padding, we used the large box for our fee estimates.
UPS Simple Rate
UPS allows you to use your box for flat-rate shipping, provided it meets the limits for one of their five sizing classes.
The cost is fixed within each size class, whether you’re sending a basketball two blocks down or a kettlebell across the country. The only variable for items in the same size bracket is shipping speed.
For these reasons, we believe that the UPS Simple Rate is the most flexible flat-rate shipping model for heavy items up to 50 lbs.
FedEx One Rate
FedEx is the only carrier that uses distance classes to determine costs for flat-rate shipping. Their three distance ranges are:
Local (Zone 2, 0-150 miles)
Regional (Zone 3 and 4, 151- 600 miles)
National (601+ miles, plus all Hawaii and Alaska shipments)
The distance factor doesn’t apply to all services. For FedEx Express Saver and FedEx 2Day, the cost remains unchanged across all distances in the continental United States. The shipping zones become a component in the pricing of enhanced services, starting with FedEx 2Day A.M.
EXAMPLE: Shipping a Medium Box locally through FedEx Priority Overnight costs $62.60. In contrast, shipping the same box through the same service will cost $147.95 if the transport distance exceeds 600 miles.
With UPS and USPS, the price of the two shipments from the example above would remain the same across all distances within the continental United States.
Packaging materials
The cost of packaging materials for shipping heavy items can be an unforeseen element of the total costs.
Let’s use the example of the large, 50-lb picture frame to assess the potential packaging costs. You might need some or all of the supplies in the table below.
| Size and weight limits for shipping a heavy package | |||
|---|---|---|---|
| UPS | FedEx | USPS | |
| Length and girth combined (inches) | 165 | 165 (130 for Express) | 108 (130 for Retail Ground, charged as oversized) |
| Length (inches) | 108 | 108 | * |
| Weight (pounds) | 150 | 150 | 70 |
BOTTOM LINE: The cost of packing materials might exceed $100, depending on your current supplies.
Suppose you spend $50 on packaging for the large picture frame. That sum is 30%-40% of the cheapest shipping options for local and interstate frame transport, which cost $135.73 and $159.91, respectively.
Other factors
Other less obvious factors might contribute to the total shipping cost.
These “hidden” costs might include additional carrier fees (coverage, special handling, collection, proof of delivery, and others), shipping and handling of hazardous materials, tracking, seasonal surcharges, etc.
Tips to reduce the cost of heavy-package shipping
Shipping heavy packages is expensive. If you’re running a business, it can weigh down your profit margins or erase them altogether. Moreover, for one-off shipments, the transport cost might exceed the value of the package.
The four strategies outlined below can help you reduce shipping costs.
Make your shipment smaller
01
If you’re sending a bulky item, the carriers might bill for shipping based on the dimensional weight instead of the actual weight.
For example, if you’re shipping an office chair that measures 20” x 20” x 35” and weighs 40 lbs, the billable weight might exceed 100 lbs. However, if you dismantle it and pack it into a box measuring 20” x 17” x 15”, you’ll pay for shipping based on the actual weight.
Here, the cost for billed weight is more than double that of the actual weight, and the cost difference might be enough to buy a new chair.
NOTE: If you can’t disassemble the object, make the package smaller by minimizing the empty space inside. If the shipping box is significantly bigger than the item you’re sending, cut the box down to size.
Explore alternative shipping companies and discount platforms
02
Shipping through a software platform like PirateShip or ParcelMonkey typically costs less because these companies negotiate bulk discounts with the carriers.
PirateShip is especially convenient for one-off heavy shipments because the platform has no monthly fees, unlike some competitors.
Get discounts through loyalty programs
03
All major carriers offer loyalty discounts to regular shippers. From UPS Savings and FedEx Advantage to the USPS Loyalty Program, these systems reward shipping volume.
NOTE: An official carrier partner, like a third-party logistics company, will typically have discounted rates as well. Red Stag Fulfillment specializes in shipping heavy items, which means greater volume-based discounts and lower prices. Contact us today for a custom quote.
Consider regional or local carriers
04
List your package on shipping aggregators* like uShip to receive bids from local carriers. A trucker or a moving company in your area might offer a good deal.
Also, regional carriers like OnTrac are sometimes a cheaper alternative to USPS, UPS, FedEx, and DHL.
*Shipping aggregators are platforms that allow multiple, typically smaller carriers to bid on transport jobs.
Need a trustworthy partner to ship heavy packages?
If you’re shipping heavy packages in bulk, teaming up with a reliable 3PL provider like Red Stag Fulfillment can transform your ecommerce business.
As specialists for heavy shipments, we handle tens of thousands of such packages per year. Plus, we appreciate that a single damaged package can hurt your profit margins, so we offer industry-leading guarantees on speed, accuracy, and safety.
Let us handle the heavy shipping so you can focus on growth.
Contact us today to start a conversation.
