Navigating FedEx’s Additional Handling Surcharge (AHS) can feel like traversing Europe without GPS, especially when these unexpected fees start impacting your bottom line. Whether you’ve recently spotted these surcharges on your invoice or you’re strategically planning your 2025 shipping budget, understanding these fees is crucial for cost-effective logistics management. Plus, with AHS fees ranging from $25 to $55, costs add up quickly if you’re shipping hundreds of packages a day.
In this comprehensive guide, we’ll demystify FedEx’s additional handling charges and show you practical ways to avoid them through smart packaging decisions—all while keeping your shipping operations running smoothly.
TL;DR:
Key takeaways
The FedEx Additional Handling Surcharge adds $25-$55 per package that exceeds standard parameters, significantly increasing shipping costs for businesses.
AHS is triggered by three main factors: weight (over 50 lbs domestic, 70 lbs international), dimensions (length over 48″, second-longest side over 30″, or combined length plus girth over 105″), or non-standard packaging.
Only the highest applicable AHS fee is charged when multiple criteria are met; they’re not all combined.
Simple strategies to avoid AHS include using standard rectangular corrugated boxes, staying under weight limits, and potentially splitting heavy shipments into multiple packages.
What you’ll learn
The exact triggers for the FedEx Additional Handling Surcharge
Current 2025 AHS rates for domestic and international shipments
How to measure your package to check if it will incur AHS
Practical packaging strategies to avoid AHS and other fees
Tips for negotiating better shipping rates with FedEx
Related surcharges that might affect your shipping costs
What is the FedEx Additional Handling Surcharge?
The FedEx Additional Handling Surcharge (AHS) is a fee applied to packages that don’t fit standard shipping parameters. This fee covers the extra labor, equipment, and processing needed for shipments that require special handling during transport.
FedEx labels these shipments “non-standard” because their size, weight, or packaging requires manual handling outside the automated system.
If you run an ecommerce business, partnering with a 3PL like Red Stag Fulfillment can help you lower your shipping costs, especially on large products that trigger AHS fees.
We’re industry leaders in big, heavy, and bulky fulfillment, and we’ve negotiated steep discounts with national carriers to enable our customers to save money on shipping costs.
Learn more about our large product fulfillment services today.
Conditions that trigger the FedEx Additional Handling Surcharge (weight, size, and packaging)
AHS is applied based on a package’s weight, size, or packaging. Let’s go over the exact conditions that cause these surcharges so you can better manage your shipping expenses.
Weight
FedEx applies weight-based AHS to:
U.S. domestic packages weighing over 50 lbs
International packages weighing over 70 lbs
Size
Even lightweight packages can trigger additional handling fees if they exceed certain dimensions:
Length exceeding 48″ (longest side)
Second-longest side exceeding 30″
Combined length plus girth (2 x width + 2 x height) exceeding 105″
NOTE: Packages meeting these dimensional criteria will be subject to a minimum billable weight of 40 lbs, regardless of their actual weight.
Packaging
FedEx may apply additional handling charges for non-standard packaging, including:
Not fully enclosed: Items must be completely enclosed in a rigid corrugated cardboard box. Partial enclosures or irregular coverings may incur extra fees. The only exception is FedEx-approved soft packaging, such as poly bags and padded mailers. (Read FedEx’s “How to Pack” guide for more information.)
Non-cardboard materials: Packages made from wood, metal, canvas, leather, hard plastic, or Styrofoam require a cardboard box to avoid surcharges.
Shrink-wrap/stretch film: Wrapping alone isn’t sufficient; items must be inside a box or poly bag that meets FedEx’s standards.
Oversized soft packs: Soft-sided packs (poly bags, padded mailers) exceeding 18″ x 13″ x 5″ must be boxed.
Round or cylindrical packages: Items like mailing tubes, tires, and drums must be placed inside a rectangular cardboard box.
Protrusions: Packages with wheels, handles, or banding must be fully enclosed to avoid damage. Exposed parts, even if the item is otherwise boxed, may cause damage or incur extra fees.
Potential for damage: Irregular shapes, unsecured straps, or exposed edges must be repackaged to prevent interference with sorting systems.
PRO TIP: Review your product dimensions and packaging materials to identify potential surcharges before they impact your bottom line. Small adjustments to your packaging strategy can lead to significant shipping cost savings.
Freight and pallet considerations
When shipping large items with FedEx Express Freight, you may incur AHS if any side is longer than 62″.
This surcharge is applied individually to each freight unit, regardless of whether multiple pieces are consolidated into a single package. For example, if you ship a pallet with three crates strapped together and two of the crates individually exceed 62″ in length, the surcharge would apply to each oversized crate, not just once for the entire pallet.
NOTE: Pallets with irregular shapes, fragile contents, or uneven weight distribution are subject to a separate Non-Stackable Surcharge. As a result, a single freight handling unit might incur both the standard AHS and the Non-Stackable Surcharge.
Additional Handling Surcharge rates as of 2025
AHS rates and criteria are adjusted annually. Below are the rates for 2025, outlining charges based on package dimensions, weight, and type for both domestic and international shipments, as well as FedEx freight shipments.
US domestic package
AHS for domestic packages is divided into three sub-categories based on specific criteria, each with different pricing. Below are the per-package prices for each shipping zone (distance).
| AHS type | Zone 2 | Zones 3-4 | Zones 5-6 | Zones 7+ |
|---|---|---|---|---|
| Dimension-based | $28 | $31 | $34 | $38 |
| Weight-based | $43.50 | $47.50 | $50.50 | $55 |
| Packaging-based | $25 | $29 | $30.50 | $31.50 |
The rates for Zones 3–4 are also applicable to shipments within U.S. Zone 22 (Intra-Alaska), U.S. Zone 14 (Intra-Oahu), and U.S. Intra-Hawaii. Similarly, the Zones 7+ rate applies to shipments from the U.S. to Puerto Rico.
International package
For international packages, the AHS per-package fees are as follows:
| AHS type | Fee |
|---|---|
| Dimension-based | $27 |
| Weight-based | $38 |
| Packaging-based | $27 |
FedEx freight
Per-unit AHS rates for FedEx Freight shipments are:
| Freight type | Fee |
|---|---|
| US Express Freight | $270 |
| International Freight | $260 |
Important pricing notes
FedEx’s guidelines for the Additional Handling Surcharge (AHS) can be quite complex, so let’s break them down.
One of the key points to note is that if a package meets the criteria for multiple Additional Handling Surcharges, only the surcharge with the highest fee will be applied, not all of them.
For example, an improperly packaged car part weighing 60 lbs, with a combined length plus girth of 110″, shipped to Zone 3, would incur a $47.50 AHS fee. This is the weight-based AHS, which is higher than the $31 dimension-based and $29 packaging-based AHS fees.
A related and more expensive charge is the Oversize Charge. This applies to large packages that exceed 96″ in length or 130″ in length and girth. The charge is based on the actual or dimensional weight, whichever is greater. You’ll pay a 90-lbs minimum billable weight unless you’re using express international shipping.
If your package triggers the Oversize Charge, dimension-based AHS will not apply, but weight-based or packaging-based AHS may still be charged, depending on which is greater.
Here are a couple of examples of how the Oversize Charge and AHS interact:
Industrial printer:
Box dimensions: 50″ × 30″ × 20″
Combined calculation: 50″ + (2 × 30″) + (2 × 20″) = 50″ + 60″ + 40″ = 150″
Weight: 80 lbs
Result: Exceeds the 130″ limit and 50 lbs AHS threshold, so both an Oversize Charge and weight-based AHS apply.
Box dimensions: 80″ × 20″ × 20″
Combined calculation: 80″ + (2 × 20″) + (2 × 20″) = 80″ + 40″ + 40″ = 160″
Weight: 45 lbs
Result: Exceeds the 130″ limit, but the weight is under the 50 lbs AHS threshold. Only the Oversize Charge is applied.
Regarding the packaging-based AHS, note that a package’s shape can change during transit due to handling, which may impact its eligibility for surcharges or trigger adjustments.
For example, if a TV is poorly packaged and its box bursts open, revealing the styrofoam inside, it could incur a packaging-based surcharge. Items that commonly incur the packaging-based AHS are tires, as they’re often not properly packed in a standard corrugated box.
How to determine if your package will incur the Additional Handling Surcharge
Here’s how to determine if your package will trigger AHS.
Check package dimensions and weight
Once you’ve packed your item, measure and weigh it. If your figures exceed any of the following dimensions, the AHS applies:
The Longest side 48″, second-longest side 30″
Length plus girth (L + 2W + 2H) 105″
50 lbs (US) or 70 lbs (international)
Even being slightly over the limit will trigger the surcharge.
Assess package materials
Carriers charge more for packages that don’t meet standard packaging requirements.
Check if your package is properly enclosed in corrugated cardboard or FedEx-approved soft packaging.
Verify that the packaging provides adequate protection.
Ensure the package can withstand standard automated handling.
Confirm your package doesn’t have exposed sharp edges or protrusions.
Identify irregular shapes
Packages with non-standard shapes require special handling and trigger AHS. Here are a few things to watch for:
Check for any irregular shapes, protrusions, or cylindrical packaging.
Measure against specific dimensional limits for soft packs.
Determine if your packaging has uneven weight distribution.
Check if special orientation is required during shipping.
Cylindrical tubes, triangular boxes, and irregularly shaped items almost always trigger additional handling surcharges.
Check stackability for freight shipments
For larger freight shipments, stackability affects handling charges.
Determine if pallets can be safely stacked.
Check if shipments require a “Do Not Stack” designation.
Verify that pallet dimensions meet standard requirements.
Secure your package properly to the pallet.
Review these four shipment factors to see if your package may incur surcharges. When possible, adjust packaging to meet standard requirements and avoid extra costs.
When shipping with FedEx, the Additional Handling Surcharge isn’t the only fee that hurts your bottom line. Take a moment to familiarize yourself with FedEx’s other potential charges:
- Oversize Charge: Packages over 96″ in length or over 130″ in length + girth incur this premium fee in lieu of dimension‑based handling.
- Unauthorized Package Charge: Shipments exceeding Ground size limits face a hefty penalty or may be refused outright.
- Address Correction: Incorrect or incomplete addresses trigger this extra fee on top of any handling surcharges.
- Delivery Area Surcharge: Remote or hard‑to‑reach destinations incur an additional charge.
- Residential Delivery Charge: Home deliveries (vs. commercial addresses) carry this separate fee.
- Fuel Surcharge: This variable percentage, which fluctuates with fuel prices, is added to base rates and all surcharges.
- Demand Surcharge: FedEx tacks on an extra fee during peak periods, such as the holiday season. Check the current FedEx Demand Surcharge rates for up-to-date information.
NOTE: Multiple fees (handling, oversize, fuel, etc.) can apply together, driving up total costs.
Tips on avoiding AHS and other surcharges
Shipping surcharges quietly chip away at your profits, but with a few smart adjustments to your packaging and shipping process, you can reduce or eliminate many of these costs.
Pack smarter to avoid extra fees
Choose standard boxes—FedEx applies surcharges to non-standard packaging, so stick with standard, corrugated, rectangular boxes if you don’t want to pay the AHS fee. Good places to buy boxes of many sizes are:
Check for odd shapes and protrusions—Irregular shapes like tubes, circular packages, or items with protruding parts aren’t just likely to trigger Additional Handling Surcharges; they can also compromise the safety of your package. So encase odd shapes or protrusions in larger packaging or disassemble the item for compact shipping.
Pack items securely—Loose or shifting items in a large box can distort packaging and trigger AHS during shipping.
Decrease packing materials—If your package is just over the 50 lb weight limit, try removing excess packing materials to avoid AHS.
Double ip on boxes—Depending on what you’re shipping, two lighter boxes can be cheaper than a single heavy one if it incurs AHS. Use FedEx’s Shipping Calculator to compare the rates.
Reorganize—If you’re exceeding length parameters on a single side, rotate items to shorten the longest side and use snug packaging to reduce dimensional weight.
Oversized boxes that meet the dimensional AHS criteria are also billed at a 40 lb minimum, even if the actual weight is lower. FedEx will treat it as weighing at least 40 lbs, further driving up shipping costs.
PRO TIP: If you need an adjustable box, consider using a telescoping box. They can be configured to various lengths to fit your shipment.
Choose the right shipping service
For oversized or heavy items, FedEx Freight could be more cost-effective than parcel shipping.
Compare Ground and Express, as surcharge thresholds and rates vary, and sometimes the faster option can be cheaper.
Flat-rate options like FedEx One Rate can also help avoid weight- or size-based fees when the item qualifies.
Streamline your shipping process
Train your team to spot surcharge triggers. To avoid AHS, consider adding a final check for weight and dimensions before printing labels.
Audit your FedEx invoices regularly. If certain SKUs trigger surcharges often, adjust how they’re packed. Small changes can lead to big savings over time.
Partner with Red Stag Fulfillment to get better shipping rates
Don’t let Additional Handling Surcharges eat into your profits. If you’re a high-volume shipper, you have more negotiating power than you might think. And with the right fulfillment partner, you can turn that volume into leverage.
As specialists in big, bulky, and heavy fulfillment, Red Stag Fulfillment can offer steep discounts on AHS and other shipping fees by leveraging our volume in carrier negotiations. If you want to take advantage of our discounts and increase your brand’s bottom line, reach out to us today.
