FedEx oversized fees explained [2025 complete guide]

FedEx shipping rates are clear-cut, but their oversized fees can be a costly surprise. One packaging mistake or policy oversight can trigger substantial surcharges and slash your profit margins.

With 12 years of specialized experience in large and heavy fulfillment, we’ve mastered all the FedEx size- and weight-related surcharges—from additional-handling and oversized-package fees to demand surcharges and the hefty $1,325 Ground Unauthorized Charge.

In this guide, we break down everything you need to know about these fees, including specific triggers and amounts, common pitfalls, and strategies to lower or eliminate the added costs.

What you’ll learn

FedEx oversized fees explained

FedEx oversized fees explained

Additional Handling Surcharges (AHS)

FedEx applies an Additional Handling Surcharge to packages that exceed certain size and weight thresholds or have nonstandard packaging. Also known as AHS, these surcharges can be triggered by one of the following package characteristics:

Below, we analyze these additional-handling surcharges, including their specific amounts and how they apply in different scenarios.

Dimension-based AHS

Policy: FedEx will apply a dimension-based additional handling surcharge if a package meets any of the following criteria:

*Girth=2 x width + 2 x height.

The surcharge amount is determined per shipping zone and doesn’t vary by the offending dimension. For example, a Zone-2 shipment will incur the same AHS, whether the charge is triggered by the package’s length or combined weight and girth.

To calculate dimensional weight, multiply length x height x width (rounded to the nearest inch) and divide by 139. Then, round any decimal results up to the higher whole pound. Alternatively, calculate the specific DIM weight for your package using our dimensional weight calculator.

The table below shows the specific amounts of the size-based AHS fee for domestic shipping zones and on international routes.

*The Zone 3-4 surcharge is also applied to shipments on the following routes: Intra-Oahu (U.S. Zone 14), Intra-Alaska (U.S. Zone 22), and U.S. Intra Hawaii, while the Zone 7+ fee also applies to shipments going from the United States to Puerto Rico.

In this example, both the actual and the dimensional weight are lower than 40 lbs, so FedEx will treat the package as a 40-lb parcel when calculating the base rates.

Example: Consider three shipments—an office chair, a frameless canvas, and a framed painting. As the table below illustrates, these three shipments might trigger the dimension-based AHS by breaching different dimension thresholds.

Weight-based AHS

Policy: FedEx applies a weight-based additional handling surcharge if a package weighs more than 50 lbs (U.S. Package Services) or 70 lbs (International Package Services).

The table below shows the weight-based AHS amounts for domestic shipping zones and international routes.

Example: Consider a shipment that breaches all AHS thresholds, like a refrigerator that measures 65″ x 31″ x 26″ and weighs 90 lbs. Since both the size and weight AHS are triggered, only the higher will apply.

If you ship this refrigerator within Zone 2, the potential AHS fees triggered by size and weight are $28 and $43.50, respectively. In this situation, FedEx will apply the higher weight-based surcharge and add $43.50 to your shipping costs.

Applicable services for AHS–domestic, international, and freight

FedEx applies the Additional Handling Surcharge to all domestic and international package services and Express Freight services, except FedEx International Premium.

The table below shows the AHS amounts for FedEx Express Freight services:

FedEx Oversize Charge

FedEx’s Oversize Charge applies a minimum billable weight to packages exceeding 96″ in length or 130″ in combined length and girth. Some core aspects of the policy differ between domestic and international shipments, so we’ve split this section accordingly.

Oversize Charge for domestic packages

Policy: If a domestic package exceeds 96″ in length or 130″ in combined length and girth, FedEx will add the Oversize Charge to the base rate and apply a minimum billable weight of 90 lbs.

Compared to U.S. Package Services, the Oversize Charge is $35 to $50 higher for FedEx Home Delivery shipments, as shown in the table below.

*Note: Zone 3-4 rates also apply to intra-Alaska and intra-Oahu shipments (U.S. Zone 22 and Zone 14, respectively), while Zone 7 rates apply to packages shipped from the United States to Puerto Rico.

Example: A 35-lb shipment that measures 91″ x 10″ x 10″ has a combined length and girth of 131″, which triggers the FedEx Oversize Charge. Moreover, the applicable weight for FedEx shipping charges will be the greatest of actual, dimensional, and minimum billable weight.

The table below illustrates how FedEx determines the billable weight for this package.

Oversize Charge for international packages

Policy: International packages that trigger the Oversize Charge incur a flat $190 add-on fee but are exempt from the 90-lb minimum billable weight. However, if a package on international routes also breaches the dimension-based AHS limits, FedEx applies a minimum billable weight of 40 lbs.

Example: Consider shipping a slender textile roll internationally. If the packaged roll measures 97″ x 7″ x 7″ and weighs 30 lbs, it breaches two relevant size thresholds—that of the Oversize Charge and the dimension-based AHS.

On the other hand, both the actual weight (30 lbs) and the dimensional weight (35 lbs) are lower than 40 lbs. In this scenario, FedEx will base their rates on the minimum billable weight, as illustrated in the table below.

FedEx Ground Unauthorized Package Charge

Policy: FedEx may refuse parcel shipping or add a $1,325 per-package surcharge when shipments exceed any of these limits:

If they accept the shipment, it’s subject to a minimum billable weight of 90 lbs.

Example: If you’re shipping a 50-lb package that measures 60″ x 25″ x 25″, its combined length and girth is 160″, so it doesn’t breach any of the maximum size limits.

However, suppose the package changes shape/dimensions during transit and FedEx remeasures it at 55″ x 28″ x 28″. In that case, the new combined length and girth of 167″ exceeds the unauthorized-package threshold and potentially triggers the $1,325 surcharge.

Applicable services: FedEx Ground, FedEx Home Delivery, and FedEx International Ground.

FedEx Demand surcharges for heavy and large packages

During peak demand periods, typically late October through mid-January, FedEx adds demand surcharges to the base shipping rates.

Formerly called “Peak,” these Demand surcharges may be unrelated to size (like Demand-Residential Delivery), but can also be directly triggered by package dimensions or weight.

Today, we’re focusing on the latter—the demand surcharges specifically related to weight and size.

Size and weight-related demand surcharges

FedEx has three demand surcharges directly related to size and weight: Demand Additional Handling, Demand Oversize Charge, and Demand Ground Unauthorized Charge.

Below, we review the key aspects of these surcharges, including the amounts, applicable services, and triggers.

Demand–Additional Handling

Demand–Oversize Charge

Demand–Ground Unauthorized

Example: Consider a Zone-2 shipment that measures 40″ x 26″ x 20″. It breaches the oversized-package thresholds because the combined weight and girth is 132″.

If you send this package with FedEx outside peak seasons, it will incur the base Oversize Charge of $205. However, if you send it around Christmas, FedEx will also add a $100 Demand–Oversize Charge to the base charges. Using the ’24/’25 season as a reference, this brings the total size-related surcharge to $305.

7 tips to lower FedEx Oversize Charges

The following section provides tips to lower or avoid the FedEx surcharges when shipping oversized packages. For each tip, we provide an example and explain what to do and what can go wrong/how it helps.

What to do: Measure the final packaged dimensions (as opposed to the pre-packaged item), as these are the only measurements that matter in FedEx’s automated systems.

What can go wrong: You might measure a box and then wrap it in an extra layer of foam sheets, which would result in inaccurate measurements. In this scenario, the FedEx system will show greater dimensions than you initially measured, which might trigger additional charges or oversized fees.

Example: If the initial measurements are 48″ x 10″ x 10″, and you add a foam-sheet layer, the new measurements might be 49″ x 11″ x 11″. The longest side of that package would trigger the Additional Handling Surcharge.

What to do: Ensure all tape and string on the package is secure. If you feel a section isn’t tightly secured and might get loose in transit, double tape it.

What can go wrong: FedEx’s automated system might recognize a loose piece of tape as the shipment’s edge and trigger size-related surcharges.

Example: If the shipping box measures 20″ x 20″ x 20″ and a 6″ piece of tape loosens in transit, FedEx might measure the package to be 26″ x 20″ x 20″. In this case, the combined length and girth of that shipment goes from 100″ to 106″, which triggers the additional-handling fee.

What to do: Round down dimensions with decimals under .5, and round up for .5 and above as shown in the table below.

What can go wrong: You might measure your package, including decimals, and conclude that it doesn’t trigger size-related surcharges. Rounded, the dimensions might exceed one of the size thresholds, resulting in higher shipping costs.

Example: Consider a shipment that measures 19.8″ x 20″ x 22.6″. If you use decimal points for calculations, the combined length will be exactly 105″, and the additional-handling fee won’t be triggered.

Rounded, the dimensions of the same package are 20″ x 20″ x 23″, which puts the combined weight and girth at 106″ and triggers the additional-handling surcharge.

What to do: Include any protruding elements or irregular shapes when measuring your package.

What can go wrong: You might asses your package’s dimensions based on the wrong end-points. FedEx will reassess these measurements, and the protruding edges might trigger a size-related surcharge.

Example: Consider shipping a vintage manual coffee grinder weighing 3 lbs. The main body and the powder bin might fit into a 5″ x 5″ x 10″ box. To use that box without disassembling the grinder, you’d need to pack around the handle. In this scenario, the width and length of the package will be assessed on the handle’s edge.

Specifically, if the handle goes 4″ beyond the grinder’s box, the final billable dimensions of this package might be closer to 9″ x 9″ x 10″. As a result, FedEx shipping fees will be based on the 6-lb dimensional weight because it’s higher than the actual weight.

On a larger scale, similar mistakes can lead to breached size thresholds or even absolute maximums, which can mean extra fees and refused shipments.

What to do: Keep specific thresholds in mind and adjust the box size and padding accordingly. For most packages, 2″–4″ of padding will offer sufficient protection.

What can go wrong: You might pay higher rates or incur extra fees by packing into an oversized box.

Example: Consider shipping a cordless grass trimmer that measures 60″ x 15″ x 10″. Optimized, the packaging might measure 63″ x 18″ x 12″. This shipment will trigger the Additional Handling Surcharge (length over 48″) without breaching the Oversize Charge threshold (130″ in combined length and girth).

In contrast, if you pack the same trimmer into a box that measures 65″ x 20″ x 14″, the combined length and girth for the package becomes 133″. That triggers the FedEx Oversize Charge and adds hundreds of dollars to your invoice.

Moreover, using a smaller box reduces shipping costs, regardless of surcharges.

What to do: Pack your items into sturdy containers and boxes that can sustain pressure. Keep in mind that packages might be stacked or pressed.

What can go wrong: Your package can change shape. The new shape might infringe on one or more of FedEx’s sizing policies.

Example: Consider shipping a 28″ x 22″ x 15″ box of malleable items, like plush toys. The initial dimensions don’t trigger any size-related surcharges in the FedEx System.

However, if the box is stacked and not sturdy enough to maintain its shape, it might compress and change dimensions to 30″ x 25″ x 13″. With the changed dimensions, the package measures 106″ in combined length and girth, which triggers the FedEx additional handling fee.

What to do: Consider splitting one oversized package that triggers FedEx surcharges into smaller shipments that don’t breach the sizing thresholds.

How it helps: You avoid the size-related fees. Even the added cost for multiple packages might be lower than the total surcharge cost.

Example: If you’re shipping a box that measures 30″ x 30″ x 25″, an Oversize Charge will be added to your invoice because the combined length and girth exceed 130″.

However, if you split that box into two shipments measuring 25″ x 25″ x 18″, you can ship the same volume (11,250 cubic inches) while lowering the size-related fees from the Oversize Charge to the Additional Handling Surcharge.

To streamline your fulfillment and benefit from volume-based discounts, join forces with a reliable 3PL provider like Red Stag Fulfillment. Contact us today for a custom quote.

What to do: Activate FedEx Multiweight pricing on your shipping account.

How it helps: FedEx Multiweight pricing simplifies the cost assessment when shipping multiple packages. The system compares the potential cost of sending multiple shipments to the cost of combining the packages into one shipment, and automatically applies the lower rate.

Example: If you’re shipping three packages weighing 60 lbs, 70 lbs, and 80 lbs, the cost of transporting them as a single Multiweight shipment might be lower than the combined cost of three separate shipments.

Leverage volume-based discounts for oversized shipments

If you’re shipping large packages for your ecommerce business, oversized fees and other surcharges can dissolve your profit margins.

A strategic partnership with a trusted 3PL provider like Red Stag Fulfillment eliminates these headaches. Fulfillment for large and heavy packages is our specialty, which allows us to negotiate volume-based discounts with FedEx and other carriers. By partnering with us, you can leverage these discounts and streamline your fulfillment.

Focus on growing your business instead of packing boxes.

Contact us today to start a conversation.