Surcharge checker

Shipping surcharges are extra fees carriers add on top of base rates for packages that require special handling, occupy extra space, or need delivery to certain areas. The most common surcharges—Additional Handling and Oversize—can add $15-100+ per package. These fees exist because unusual packages cost carriers more to process, transport, and deliver. Understanding surcharge triggers helps you avoid them through smarter packaging and carrier selection.

Both UPS and FedEx charge Additional Handling when packages meet certain criteria. As of 2025, triggers include: Weight exceeds 50 lbs (UPS: $15.75, FedEx: $16.50). Length exceeds 48 inches. Second-longest side exceeds 30 inches. Package is not fully encased in corrugated cardboard. The fee applies if ANY single trigger is met—you don't need multiple criteria. A 51-pound package in a standard box still triggers the weight-based Additional Handling fee.

Large Package surcharges (UPS) and Oversize fees (FedEx) apply to packages exceeding size thresholds. UPS Large Package: Length + Girth exceeds 130 inches (but not over 165"). Fee: $75+. UPS Over Maximum Limits: Not accepted if Length + Girth exceeds 165". FedEx Oversize: Similar thresholds with comparable fees. These surcharges are in ADDITION to any dimensional weight charges. A 60" x 30" x 30" package would be billed at DIM weight AND hit with Large Package surcharge.

Girth = (2 × Width) + (2 × Height). Length + Girth = Length + Girth. Example: 40" × 20" × 20" box. Girth = (2 × 20) + (2 × 20) = 80". Length + Girth = 40 + 80 = 120". This is under the 130" threshold—no Large Package surcharge. However, this package is over the 48" length threshold for Additional Handling based on one dimension—but since no single dimension triggers, it may avoid surcharges (verify specific carrier rules).

Delivery Area Surcharges apply to addresses carriers consider remote or expensive to service. UPS and FedEx both maintain DAS zones. Standard DAS: $4-5 per package. Extended DAS: $8-10 per package. Remote DAS: $25+ per package. Alaska/Hawaii often have separate, higher surcharges. These surcharges apply regardless of package size or weight. USPS generally has better coverage without DAS fees to rural areas.

UPS and FedEx charge residential surcharges for home deliveries: UPS Residential: ~$5.50 per package. FedEx Home Delivery: Built into rate structure. These fees are automatic when the destination is classified as residential in carrier databases. USPS does not charge residential surcharges, making it more competitive for B2C e-commerce shipping to homes.

USPS has fewer surcharges than UPS/FedEx but isn't surcharge-free: Nonmachinable surcharge: First-Class items that can't be machine-processed. Balloon-rate pricing: Large, lightweight packages may use special pricing. Dimensional weight: Applies to Ground Advantage packages over 1 cubic foot. Oversize limits: Maximum combined length + girth of 108" for most services. USPS's simpler surcharge structure often makes it more predictable for irregular packages.

1. Keep longest dimension under 48": Boxes like 47" × 18" × 18" avoid Additional Handling for length. 2. Keep second dimension under 30": Design packaging so the second-longest side stays below threshold. 3. Keep weight under 50 lbs: Split heavy shipments into multiple packages if needed. 4. Use proper packaging: Ensure items are fully encased in corrugated cardboard. 5. Check delivery area: Use USPS for remote addresses to avoid DAS. 6. Ship residential via USPS: Avoid UPS/FedEx residential surcharges. 7. Use the calculator above: Always check surcharge eligibility before shipping.

Multiple surcharges can apply to the same package. A 52-pound package shipped to a rural residential address could incur: Additional Handling (weight): $15+. Delivery Area Surcharge: $8+. Residential Surcharge: $5+. Total surcharges: $28+ ON TOP of base shipping rate. This is why understanding surcharges is critical for quoting accurate shipping costs and maintaining margins.