Shipping weights isn’t just another package delivery—it’s a challenge in itself. The sheer heaviness of items like dumbbells, kettlebells, barbells, plates, and other strength-training equipment makes the process more demanding and complex compared to shipping lighter goods.
You’re likely worrying about damage, questioning which carrier to trust, or dreading the high shipping costs.
Fortunately, you’re not alone. As fulfillment pros who specialize in big, heavy, and bulky items, we understand that shipping weights comes with unique hurdles.
In this guide, we cut through the confusion, offering practical strategies to protect and ship your equipment without overspending.
What you’ll learn:
How to properly pack weights for shipping
Step-by-step packaging techniques
Real shipping costs across carriers
When to use parcel shipping vs. Less Than Truckload (LTL) freight (including costs)
Expert tips to prevent damage and avoid insurance claim denials
Cost-saving strategies that don’t compromise protection
TL;DR:
Key takeaways
Choose FedEx Ground for packages under 150 lbs, as it’s the cheapest option, followed closely by UPS Ground.
Opt for LTL freight shipping for items 150 lbs to 15,000 lbs.
Use a double-wall corrugated box rated to support the weight of your items.
Wrap weight plates individually in stretch and bubble wrap, and use silica gel packs to prevent rust.
Stack weight plates flat to prevent shifting during transit.
PRO TIP: If you’re selling free weights or heavy gym equipment online, packaging problems and painful shipping bills can easily weigh you down.
At Red Stag Fulfillment, we’ve perfected the science of shipping heavy gear. Combining expert packaging knowledge with special carrier rates that won’t crush your bottom line, we lighten your financial—and emotional—load. Reach out now for a customized quote and let us do the heavy lifting.
9-step guide to shipping weights
Follow these steps to package your weights, avoid damage or loss during transit, and find the most affordable shipping method.
Choose a packaging method
01
Your options include DIY or professional packaging. But choose wisely, as major carriers like UPS, FedEx, and USPS won’t pay for damage caused by improper packaging.
Professional packaging
Handled by trained experts using commercial-grade materials (e.g., reinforced boxes, industrial padding).
Often includes insurance-backed guarantees for added protection.
Ideal for specialty items like Olympic bumper plates.
DIY packaging
Costs less but requires exact compliance with carrier guidelines.
Requires more time and effort.
Ideal for inexpensive or used gym weights.
When in doubt, opt for professionals. The upfront cost is often cheaper than replacing damaged weights or fighting denied claims.
Gather packing supplies
02
If you’re packing the weights yourself, gather the following supplies:
Heavy-duty cardboard box
Bubble wrap and foam padding
Air pillows or packing peanuts
Strapping and clear tape
Stretch wrap
Silica gel packets
Scissors or box cutter
Tape measure
“Fragile,” “Heavy,” ” Keep Dry,” and “This Side Up” stickers (if applicable)
PRO TIP: For weights over 50 lbs, double-box the shipment by placing a padded inner box inside a larger box. Most carriers won’t accept “overpacked” boxes that bulge or don’t have any internal structure support, as they risk damaging not only their contents but also other packages around them during transit.
Select the right box
03
When shipping heavy weights, use reinforced boxes that can handle the load and won’t break during transit.
Double-walled corrugated boxes provide superior strength and protection compared to standard shipping boxes. Heavy-duty boxes are available from packaging and home-improvement sources such as:
Choosing the right weight
Weight ratings can be a bit overwhelming, as they include ECT, burst strength, weight capacity, and more. Your best bet is to review weight recommendations from the supplier or box manufacturer, such as this guide from Uline.
Selecting the size
To determine the box size, measure the length, width, and height of your weight(s) and pick a box with 2–4 inches of extra space on each side. This allows enough room to add padding material to prevent movement and damage during transit.
PRO TIP: For a more robust packaging solution, consider using a wood crate. Although they’re more expensive and add to the shipping costs, they add extra protection against shocks and impacts. They’re also reusable in case you need to ship weights back and forth.
Protect each weight
04
If you’re shipping multiple weights, wrap each piece individually for adequate protection.
Here’s how:
01
Wrap each weight in stretch wrap to create a moisture barrier.
02
Add several layers of bubble wrap or foam padding around the entire weight for impact protection, and secure with tape.
03
Cover the edges to avoid chips and dents during transit.
Adjustable dumbbells
For adjustable dumbbells, insert foam padding or bubble wrap between individual weight plates to prevent metal-on-metal contact during transit. Secure the adjustment dial with a layer of foam and tape, and then wrap the entire unit with stretch wrap.
Box the weights
05
Your weights are now ready to be packed, so let’s prepare the box.
How to box weight plates:
01
Prepare your shipping box by creating a stable foundation with a thick layer of air pillows or packing peanuts at the bottom.
02
Stack weight plates like chips in a Pringles can. That is, lay them flat rather than standing them on up their edges.
03
Center the weights in the box.
04
Add foam padding or bubble wrap around the sides and between plates until everything stays firmly in place.
05
For uncoated iron plates, place silica gel packets throughout the box to protect against moisture and rust. Use roughly one gram of silica gel per four cubic inches. (Silica Gel Products offers a handy calculator to determine how many packets you need.) Keep stainless steel weights separate from cast iron to prevent corrosion from metal contact.
06
Fill any empty spaces with air pillows, packing peanuts, or other packing materials until the weights are completely immobilized.
How to box multiple dumbbells, kettlebells, medicine balls, and other gym equipment:
01
Line the box with a protective layer of air pillows and bubble wrap.
02
Place heavier items at the bottom.
03
Surround each item with foam or bubble wrap.
04
Add cardboard dividers and 2–4 inches of packing materials between each item.
05
Add silica gel packets (one gram per four cubic inches) if you’re shipping bare iron weights.
06
Fill voids with packing peanuts or air cushions until the weights are immobilized.
Once you’ve packed the box, give it a good shake. If you did a good job, you won’t hear or feel any movement inside the package. If you feel or hear movement, reopen the package and add more cushioning (bubble wrap, foam, or packing peanuts), verify that all items are snug, and reseal it.
NOTE: When shipping multiple heavy weights, separate the shipment into multiple boxes instead of overloading a single container. This improves safety for shipping personnel and prevents package failure during transit.
Why you shouldn’t (usually) stack weight plates on their edge
Weight plates are most vulnerable along their thin edges. In most cases, stacking them like Oreos with their thin edges nearing the top and bottom of the box significantly increases the risk of chipping, bending, or cracking during transit.
Stacking them flat (like Pringles) spreads pressure evenly across the plates’ surfaces, minimizing damage risks.
The only reasons you wouldn’t stack plates flat are if you have:
Space constraints that make flat stacking impossible.
Sufficient padding space on all sides and rigid foam or cardboard dividers between each plate.
Seal and label the package
06
Reinforce all seams with heavy-duty strapping tape. Apply it in an H-style pattern over the center and along all seams, particularly where box flaps overlap.
PRO TIP: Test the tape’s hold by pressing firmly. If it has adhered properly, it should not lift or wrinkle. If your tape doesn’t hold up, don’t add more tape; use a higher-quality type of tape instead. For boxes over 50 lbs, add a second layer of tape along all seams.
Next, apply a “Heavy” label on the top and two opposite sides of the box if your package exceeds:
35 lbs (USPS)
70 lbs (UPS)
75 lbs (FedEx)
NOTE: With UPS, you must print and attach a bright yellow UPS-specific “Heavy” label available from a retail location or online store.
Add “This Side Up,” “Keep Dry,” and “Fragile” labels as needed.
Choose a shipping method
07
Now that your weights are boxed, it’s time to select a shipping method. Options include parcel shipping and LTL.
Parcel shipping
Ideal for: Single pairs of dumbbells or small weight sets under 150 lbs.
Maximum weight limits by carrier:
USPS Priority Mail: 70 lbs
UPS/FedEx Ground: 150 lbs
DHL International Express: 154 lbs
Since weights are usually heavy as opposed to dimensionally large or bulky, dimensional (DIM) weight is unlikely to affect pricing.
Nonetheless, using an appropriately sized box can prevent unnecessary fees and makes for easier packing.
Other factors that can affect the final shipping price include:
NOTE: Standard carrier liability offers $100 of coverage. If your weights exceed this value, purchase full insurance for the value of your property.
To calculate parcel shipping costs, enter your data into the following shipping calculators:
Real-world example
To illustrate potential parcel-shipping costs, we have calculated costs for two 45-lb and two 25-lb weight plates (total weight of140 lbs) shipped in a double-walled 20″ x 20″ x 10″ box:
| Shipping from New York | ||||||
|---|---|---|---|---|---|---|
| Shipping Method | Atlantic City (~130 miles) | Chicago (~800 miles) | Los Angeles (~2450 miles) | |||
| Cost ($) | Days in Transit | Cost ($) | Days in Transit | Cost ($) | Days in Transit | |
| UPS Ground | 227.31 | 1 | 253.21 | 2 | 317.56 | 4 |
| UPS Next Day Air® Early | 600.28 | 1 | 1,510.70 | 1 | 1,744.92 | 1 |
| FedEx Ground® | 214.09 | 1 | 237.32 | 2 | 301.56 | 6 |
| FedEx First Overnight® | 589.91 | 1 | 1,563.75 | 1 | 2,041.39 | 1 |
| DHL Express | 341.65 | 1 | 961.06 | 1 | 1,198.44 | 1 |
NOTE: We didn’t include USPS because the box exceeds its 70-lb maximum weight limit.
Cheapest shipping costs
FedEx Ground offers the lowest shipping rates, with UPS Ground being a close second. Both options are also relatively fast, particularly for shorter distances.
| Weights Shipping by Distance—Cheapest Costs with Economy Shipping Methods | |||
|---|---|---|---|
| Shipping Method | Cost to Ship ~130 miles | Cost to Ship ~800 miles | Cost to Ship ~2450 miles |
| UPS Ground | $227.31 | $253.21 | $253.21 |
| FedEx Ground | $214.09 | $237.32 | $301.56 |
Priority shipping costs
If you need the weights to arrive at their destination within 24 hours, DHL Express is the cheapest option.
| Weights Shipping Costs by Distance—Priority & Expedited Shipping | |||
|---|---|---|---|
| Shipping Method | Cost to Ship ~130 miles | Cost to Ship ~800 miles | Cost to Ship ~2450 miles |
| UPS Next Day Air® Early | $600.28 | $1,510.70 | $1,744.92 |
| FedEx First Overnight® | $589.91 | $1,563.75 | $2,041.39 |
| DHL Express | $341.65 | $961.06 | $1,198.44 |
LTL (Less-than-Truckload) shipping
Ideal for: Bulk orders, commercial gym equipment, and shipments exceeding 150 lbs.
LTL shipping (aka LTL freight) is an excellent alternative to parcel shipping. It consolidates multiple shippers’ freight into the same trailer. It has a significantly higher weight limit (150–15,000 lbs) than parcel options, making it cost-effective for heavy or oversized shipments that don’t fill an entire truck. However, you’ll sacrifice some speed with LTL.
LTL shipments are typically secured to a pallet, offering excellent security and stability. Some services also allow shipping in boxes or crates, depending on the cargo.
Here’s where to acquire a pallet:
Online retailers: Platforms like ULINE, PalletTrader, and eBay sell and deliver pallets.
Freight companies: Many LTL carriers sell or rent pallets.
Local businesses: Warehouses, manufacturers, or recycling centers sell or give away pallets.
Shipping providers: Some logistics companies provide pallets and freight boxes for sale or rent.
LTL cost variables include:
Freight class: Determined by density, stowability (space required), and handling.
Distance: Zone-based rates apply for regional/national shipments.
Market conditions: Fuel surcharges and seasonal demand affect the base rate.
Additional costs can include liftgate charges (for residential addresses), added fees for locations with limited access (like rural areas), and supplemental insurance costs.
To compare prices between freight companies visit Freightquote or Freightos. These sites also allow you to select a carrier and, pay for and schedule pickup.
Real-world example
Here’s an example of a 1,000-lb shipment using a 48″ x 40″ pallet (freight class 70, residential addresses, lift gate) calculated using Freightquote.
| LTL Carrier Comparison from New York | ||||||
|---|---|---|---|---|---|---|
| LTL Carrier | Atlantic City (~130 miles) | Chicago (~800 miles) | Los Angeles (~2450 miles) | |||
| Cost ($) | Days in Transit | Cost ($) | Days in Transit | Cost ($) | Days in Transit | |
| Salson Logistics, Inc. | 160.10 | 1-2 | — | — | — | — |
| Rist Transport, Ltd. | 368.18 | 2-3 | — | — | — | — |
| Worldwide Logistics of NJ LLC | 411.13 | 1-2 | — | — | — | — |
| ABF Freight System | 603.71 | 2-3 | 908.13 | 3-4 | 872.74 | 5-6 |
| Estes Express Lines | 736.64 | 2-3 | 665.58 | 2-3 | 841.64 | 5-6 |
| TForce Freight, Inc. | 742.88 | 2-3 | 763.79 | 3-4 | 1,108.35 | 6-7 |
| A Duie Pyle Inc. | 808.44 | 1-2 | — | — | — | — |
| Ward Trucking, LLC | 861.36 | 2-3 | 841.19 | 4-5 | 1,290.49 | 6-7 |
| Roadrunner Transportation Services Inc | — | — | 704.50 | 3-4 | 882.36 | 5-6 |
| Pitt Ohio Express | — | — | 737.72 | 3-4 | — | — |
| Hercules | — | — | — | — | 729.68 | 6-7 |
| Cal-Cleve Ltd. | — | — | — | — | 904.18 | 4-5 |
Schedule pickup or drop-off of your shipment
08
Choose between carrier pickup or drop off your shipment yourself.
Carrier pickups from your home or business are convenient, while local drop-offs provide greater flexibility and potential savings.
If you opt for a local drop-off and can’t carry the heavy package yourself, call ahead to confirm that the facility staff can help with loading.
PRO TIP: Save on residential delivery fees by shipping the weights to and from a business address.
Track and inspect the delivery
09
After shipping your weights, these follow-up steps can ensure a smooth delivery:
Share tracking information with recipients immediately after shipping. This reduces uncertainty and minimizes support inquiries.
Provide any special handling instructions to the delivery driver.
Tell recipients to arrange unloading assistance if necessary.
Ask recipients to inspect the weights upon arrival and before signing for the delivery.
Instruct recipients to keep all original packaging until they’ve completed a full inspection, as carriers typically require proof of packaging for any damage claims.
Tell recipients to immediately notify the carrier if damage has occurred and to reject the delivery if needed.
Let Red Stag Fulfillment lighten your shipping load
Shipping weights requires careful handling. While DIY shipping is possible with the right preparation and packaging, it can also be complex, time-consuming, and risky.
The potential for damage, denied insurance claims, and the physical demands involved often make professional fulfillment services the smarter choice for many businesses.
At Red Stag Fulfillment, we specialize in shipping heavy, bulky items like weights and exercise equipment. Our expertise in this niche means we understand the challenges of shipping weights and have developed processes for safe, on-time delivery.
Our team uses professional-grade materials and proven protocols to protect your weights during storage and shipping.
If we make a mistake, we don’t just fix it—we compensate you for the inconvenience.
Whether you’re shipping a few weight plates or managing large, regular shipments of gym equipment, Red Stag Fulfillment can streamline your operations.
Contact us today to learn how our expertise with heavy items can benefit your business and bring peace of mind to your shipping process.
