In today’s ecommerce landscape, unexpected shipping costs can make or break your profit margins. The UPS Additional Handling Surcharge (AHS) is one of these hidden costs that catches many shippers off guard, potentially turning profitable sales into losses.
This comprehensive guide breaks down everything you need to know about the UPS Additional Handling Surcharge, from the exact criteria that trigger the fee to practical strategies for avoiding or minimizing its impact. Whether you’re shipping oversized items, heavy packages, or uniquely shaped products, understanding this surcharge is crucial for maintaining your bottom line.
TL;DR:
Key takeaways
The Additional Handling Surcharge applies if the physical weight or dimensional weight exceeds 50 lbs.
The longest side exceeds 48″ or the second-longest side exceeds 30″.
The length plus width exceeds 105″ or the packaging is cylindrical.
The outer packaging is not corrugated cardboard or the UPS Additional Handling Surcharge can add $25–$52.75 per package.
What is a UPS Additional Handling Surcharge?
The UPS Additional Handling Surcharge is a fee applied to UPS packages that require extra processing or specialized handling not covered by UPS’ standard handling systems. It covers the additional cost of transporting shipments that don’t fit the mold of standard-sized packages.
UPS charges this fee because shipments that are either too heavy, too big, or improperly packaged require extra labor and can impact the efficiency of UPS’ highly automated shipping network.
Over the past five years, UPS delivery fees for large packages have effectively doubled—making it more important than ever to understand how to calculate hidden costs, sidestep fees, and protect profit margins.
PRO TIP: If you sell bulky products online, Red Stag Fulfillment can help you lower your shipping fees. We’re a 3PL that specializes in big, heavy, and bulky fulfillment, and part of that specialization comes from the deep discounts we’ve negotiated with major carriers on AHS and other fees that big products get hit with.
Learn more about our big, heavy, and bulky fulfillment services today.
UPS Additional Handling Surcharge criteria
The UPS Additional Handling Surcharge is triggered when a package meets one or more of the following criteria listed in the carrier’s Terms and Conditions of Service/Carriage.
Weight. A package exceeds 50 lbs or a shipment where the average weight per package exceeds 50 lbs.
Dimensions. A package where the longest side exceeds 48″, the second-longest side exceeds 30″, or the length plus width exceeds 105″.
Packaging. Any cylindrical-like item or any package that: is not fully encapsulated in an outer shipping container made of corrugated cardboard; is bound with metal, plastic, or cloth banding; or has wheels, casters, handles, or straps.
The table below provides a more detailed breakdown of these criteria.
| Criteria | Rule |
|---|---|
| Weight | |
| Package weight (domestic shipment) | Exceeds 50 lbs |
| Package weight (international shipment) | Exceeds 55 lbs |
| Average package weight (multi-package shipment) | Exceeds 50 lbs |
| Unspecified weight | Exceeds 50 lbs with weight not specified in system |
| Dimensions | |
| Longest side | Exceeds 48″ |
| Second-longest side | Exceeds 30″ |
| Length plus girth | Exceeds 105″ |
| Packaging | |
| Outer packaging | Externally banded or not fully encased in corrugated cardboard |
| Shape | Cylindrical (e.g., tires, tubes, and barrels) |
| Material | Made of foam, wood, metal, or hard plastic |
| Characteristics | Could damage or entangle other shipments and UPS sorting systems |
NOTE: The UPS Additional Handling Surcharge will not be assessed or applied when a Large Package Surcharge is already applicable.
2025 UPS Additional Handling Surcharge rates
This table reflects the UPS Additional Handling Surcharge rates per reason after the price increased on December 23, 2024:
| Reason | Zone 2 | Zones 3–4 | Zones 5+ | International |
|---|---|---|---|---|
| Weight | $43.50 | $47.50 | $52.75 | $34.00 |
| Dimensions | $28.00 | $31.00 | $36.00 | $34.00 |
| Packaging | $25.00 | $29.00 | $31.00 | $34.00 |
You can only be charged one additional handling fee per package. If your package meets multiple criteria, you’ll be charged the most expensive fee—prioritized by weight, then size, then packaging.
The rate for an Additional Handling Surcharge is based on the greater of the dimensional weight or the actual weight, and it’s subject to the minimum billable weight of 40 lbs for all zones.
NOTE: When using the UPS.com shipping system to book a shipment, the Additional Handling Surcharge is automatically calculated for packages that meet the dimensions criteria, and the fee is automatically applied to your total shipping cost for packages that meet the weight criteria.
How to calculate UPS Additional Handling Surcharge
You’ll need four pieces of information to calculate the surcharge:
Your package weight (or average package weight if a shipment contains more than one package)
The dimensions of your package
The packaging material and shape of the package
Your shipping destination
First, measure the length, height, and width of your package.
If the longest side exceeds 48″ but is under 96″, the second-longest side exceeds 30″, or the length plus the width exceeds 105″ but is under 130″, your package will be assessed for the Additional Handling Surcharge.
If any of the sides exceed 96″ or the length plus width exceeds 130″, the Large Package Surcharge will apply instead.
Next, weigh your package. You’ll need to know the actual and dimensional weights as well, as you’ll be charged based on the greater of the two.
To find the dimensional weight of a package, multiply the length, width, and height of your package (in inches) and divide the total by 166 for retail shipments or 139 for regular shipments.
Alternatively, you can use our free dimensional weight calculator to save time.
If the greater of the two weights exceeds 50 lbs, the Additional Handling Surcharge applies.
If the shape of the package is cylindrical or your outer packaging has external banding or is made of any material besides corrugated cardboard, the Additional Handling Surcharge applies.
Use the table above to determine the surcharge rate for your shipping zone based on the highest-priority reason for surcharge.
Examples
To give you an idea of how this calculation works, here are some real-world examples:
Shipping a box of books:
Destination: Zone 5
Longest side: 15″
Second-longest side: 10″
Length plus width: 25″
Actual weight: 20 lbs
Dimensional weight: 6 lbs
Packaging: Corrugated cardboard
Result: None of the Additional Handling Surcharge criteria is met, so no surcharge applies.
Destination: Zone 2
Longest side: 65″
Second-longest side: 10″
Length plus width: 75″
Actual weight: 15 lbs
Dimensional weight: 24 lbs
Packaging: Corrugated cardboard
Result: The longest side exceeds the 48″ limit, so the dimension surcharge for Zone 2 ($28) applies.
Shipping a TV:
Destination: Zone 3
Longest side: 45”
Second-longest side: 25”
Length plus width: 55”
Actual weight: 40 lbs
Dimensional weight: 81 lbs
Packaging: Corrugated cardboard with plastic banding
Result: The dimensional weight exceeds the 50 lb limit and the packaging is externally banded, so the higher-priority weight surcharge for Zones 3–4 ($47.50) applies.
Destination: Zone 4
Longest side: 100”
Second-longest side: 40”
Length plus width: 140”
Actual weight: 20 lbs
Dimensional weight: 144 lbs
Packaging: Corrugated cardboard
Result: The longest side exceeds 90”, so the Large Package Surcharge applies, and the Additional Handling Surcharge does not apply.
Calculating the true shipping cost of your package requires knowledge of all the hidden fees and extra costs you may incur.
Other UPS surcharges to be aware of:
Large Package Surcharge: Applies to packages that exceed specific UPS dimensional limits
Dimensional Weight: Applies when the dimensional weight exceeds the actual weight
Residential Delivery: Applies to shipments requiring home delivery
Fuel: Varies depending on current fuel costs
Address Correction: Applies when the delivery address is incorrect or incomplete
Remote Area: Applies when a package is delivered to or collected from certain ZIP codes within Alaska and Hawaii
Some circumstances warrant additional surcharges, such as Dangerous Goods, Saturday Delivery, Proof of Delivery, and Surge Fees.
Tips for avoiding the Additional Handling Surcharge
When it comes to minimizing shipping costs, simple changes can make a big difference. By making strategic adjustments to your packaging and considering various shipping services, you can effectively avoid Additional Handling Surcharges and streamline your shipping process.
Optimize your packaging
It’s not always possible to keep your packaging dimensions and weight below the Additional Handling Surcharge limits, but in some cases there may be a workaround.
For example, if you’re shipping an item that can be easily disassembled and separated into multiple packages, you could split the shipment to keep the weight and dimensions of each individual shipment below the limits.
Additionally, you can avoid triggering the packaging rule by ensuring your outer packaging comprises corrugated cardboard.
Compare other carrier options
Another way to avoid the UPS Additional Handling Surcharge is to go with a different carrier.
Other carriers typically have their own fees for additional handling, but some may have higher limits that allow you to avoid the extra costs.
You can compare carrier pricing for differently weighted packages using our free shipping guides:
Alternatively, consider freight services for oversized or heavy packages. Using less-than-truckload (LTL) or full-truckload (FTL) shipping often provides better value for shipments that trigger additional handling surcharges.
PRO TIP: If you’re shipping a cylindrical-like item, such as a tire or a globe, and you wish to avoid the Additional Handling Surcharge, place the item inside a non-cylindrical carton that satisfies the dimensional and weight limits and the packaging rule.
Negotiate better UPS rates with smarter contracts
Standard UPS shipping rates are fixed for one-off shipments.
However, frequent shippers—especially businesses—can gain access to substantial discounts through smart contract negotiation. By leveraging volume discounts and strategic planning, you can significantly lower your UPS shipping costs.
The solution is a smart UPS contract.
Your UPS contract should cover:
Annual volume commitments for cheaper rates
Service level guarantees for better shipping standards
Peak season adjustments for predictable shipping costs
Did you know you that if you’re an ecommerce company, you can get access to greater discounts by partnering with Red Stag Fulfillment?
As a third-party logistics (3PL) specialist, we’re able to leverage the combined shipping volume of all our clients to acquire significant discounts that we pass on to your business.
You can benefit from reduced surcharges and pre-negotiated shipping rates without needing to manage the carrier relationship yourself. To learn more about partnering with Red Stag Fulfillment, reach out to our friendly team for a chat today.
