How to Cut Oversized Shipping Costs: Insider Tips from a 3PL

Shipping oversized items can be expensive, with carriers charging additional handling fees, dimensional weight pricing, and shipping surcharges that quickly add up. Businesses selling products like e-bikes, furniture, and outdoor equipment need cost-effective shipping strategies to stay competitive. By working with an experienced 3PL, you can take advantage of specialized solutions that significantly reduce oversized shipping costs.

Understanding the Costs of Oversized Shipping

Carriers like UPS, FedEx, and freight companies apply different pricing structures to oversized shipments, which often include:

Dimensional weight pricing (DIM weight): Carriers charge based on the package's volume rather than actual weight.

Additional handling fees: Applied to packages exceeding certain weight or size thresholds.

Oversized package surcharges: Extra charges for exceeding standard dimensions.

Peak season surcharges: Higher fees applied during peak shipping periods.

These costs make it crucial for businesses to optimize how they pack, ship, and choose their carriers.

Oversized Shipping Charges by Carrier

Here’s a breakdown of oversized shipping charges by carrier (as of 2024):

UPS

Additional Handling Fee: $20.50 (applies to packages over 50 lbs or exceeding 48" in length)

Large Package Surcharge: $165 for domestic shipments (applies if length exceeds 96" or length + girth exceeds 130")

Over Maximum Limit: $1,150 (if a package exceeds 150 lbs or is over 108" in length)

For more information, visit shipping oversized items with UPS.

FedEx

Additional Handling Fee: $21.50 (applies to packages over 50 lbs or 48" in length)

Oversize Charge: $145 per package (applies if length exceeds 96" or length + girth exceeds 130")

Unauthorized Package Charge: $1,025 (if a package exceeds FedEx's max size limits)

USPS

Dimensional Weight Pricing: Applies to packages over 1 cubic foot in volume

Nonstandard Length Fees:

Over 22" but ≤ 30": $4.00 surcharge

Over 30" but ≤ 108": $15.00 surcharge

Exceeding 108": Not accepted via standard USPS services

Additional Handling Fee: $20.50 (applies to packages over 50 lbs or exceeding 48" in length)

Large Package Surcharge: $165 for domestic shipments (applies if length exceeds 96" or length + girth exceeds 130")

Over Maximum Limit: $1,150 (if a package exceeds 150 lbs or is over 108" in length)

For more information, visit shipping oversized items with UPS.

Additional Handling Fee: $21.50 (applies to packages over 50 lbs or 48" in length)

Oversize Charge: $145 per package (applies if length exceeds 96" or length + girth exceeds 130")

Unauthorized Package Charge: $1,025 (if a package exceeds FedEx's max size limits)

Dimensional Weight Pricing: Applies to packages over 1 cubic foot in volume

Nonstandard Length Fees:

Over 22" but ≤ 30": $4.00 surcharge

Over 30" but ≤ 108": $15.00 surcharge

Exceeding 108": Not accepted via standard USPS services

Over 22" but ≤ 30": $4.00 surcharge

Over 30" but ≤ 108": $15.00 surcharge

Exceeding 108": Not accepted via standard USPS services

These charges can quickly add up, making it critical for businesses to optimize their packaging and shipping strategies.

How to Cut Costs on Oversized Shipments

1. Use a 3PL with Negotiated Carrier Discounts

One of the best ways to reduce oversized shipping costs is by leveraging bulk shipping discounts. 3PL Center has negotiated lower rates with major carriers, offering customers substantial savings on large and bulky shipments. This includes:

Reduced additional handling fees

Waived peak season surcharges on oversized items

Competitive LTL (Less-than-Truckload) rates for palletized shipments

By partnering with a 3PL, businesses can tap into these discounts instead of paying full retail carrier rates.

2. Optimize Packaging for DIM Weight Savings

Since carriers use DIM weight pricing, inefficient packaging can drive up shipping costs. A 3PL with box optimization software—like 3PL Center—ensures each shipment is packed in the most cost-effective way.

Using the smallest possible box that fits the product

Reducing empty space inside the box to avoid dimensional weight charges

Using alternative packing materials to stay within carrier thresholds

This helps businesses avoid unnecessary DIM weight fees and lower shipping expenses.

3. Choose the Right Shipping Method

Many businesses default to parcel shipping, but for oversized items, LTL freight can be a more affordable alternative. 3PL Center helps customers rate shop between different shipping methods, ensuring they get the lowest-cost option based on package size, weight, and destination.

4. Consolidate Shipments for Cost Savings

Shipping multiple items separately increases costs, especially with oversized products. 3PL Center offers consolidation services, grouping multiple orders into fewer shipments to cut down on per-package fees. This works especially well for businesses shipping large items in bulk to retailers or distribution centers.

5. Ship from Multiple Warehouses to Reduce Transit Costs

The farther a package has to travel, the more it costs. 3PL Center’s strategic warehouse locations allow businesses to ship oversized items from the closest facility to the customer, reducing shipping zones and lowering costs.

How 3PL Center Can Help You Save on Oversized Shipping

3PL Center specializes in handling oversized shipments, offering:

Exclusive carrier discounts on large packages

Customized storage solutions for bulky items like bikes, furniture, and outdoor equipment

Specialized equipment (boom lifts, slip sheet machines, forklift clamps) for oversized handling

Rate shopping between 3PL Center’s carrier rates and customers’ carrier rates

Fast fulfillment from multiple warehouse locations, cutting down on shipping zones

By working with an experienced 3PL, businesses can eliminate unnecessary shipping costs while improving efficiency and delivery speed.