Understanding FedEx Additional Handling for Packages Over 165 Inches

September 27, 2024
by Anthony Robinson

FedEx, one of the leading shipping companies in the world, has a policy for handling packages that exceed certain size and weight limits. This policy is known as FedEx Additional Handling, and it applies to packages that have a length greater than 165 inches. In this article, we will help you understand what FedEx Additional Handling is, why it matters, how it is calculated, and how it can impact your shipping costs. We will also provide you with tips and best practices for avoiding additional handling fees and for shipping large items with FedEx.

What is FedEx Additional Handling and Why Does it Matter?

FedEx Additional Handling is a surcharge that applies to packages that exceed certain size and weight limits. This surcharge is applied in addition to the regular shipping charges and can significantly increase the cost of shipping. It matters because it affects the competitiveness and profitability of businesses that rely on shipping large items through FedEx. If not properly understood and managed, it can also lead to delays, damaged packages, and dissatisfied customers.

It is important to note that the size and weight limits that trigger the FedEx Additional Handling surcharge vary depending on the shipping service selected. For example, the limit for FedEx Express is different from that of FedEx Ground. Additionally, the surcharge is not limited to just oversized or heavy packages. It can also apply to packages that are not properly packaged or have irregular shapes, such as tubes or rolls. Therefore, it is crucial for businesses to carefully review the FedEx Additional Handling guidelines and ensure that their packages meet the requirements to avoid unexpected fees and complications.

When Does FedEx Impose Additional Handling Charges?

FedEx imposes additional handling charges on packages that are larger than 165 inches in length and girth combined or that exceed certain weight limits, depending on the service type and destination. For example, FedEx Ground may impose additional handling charges on packages that weigh more than 70 pounds or that have a length greater than 108 inches. FedEx Express may impose additional handling charges on packages that weigh more than 150 pounds or that have a length greater than 119 inches. Additionally, FedEx may impose additional handling charges on packages that are not properly packed or labeled, or that require special handling due to their contents or fragility.

It is important to note that FedEx also imposes additional handling charges on packages that require special handling due to their shape or dimensions. For instance, packages that are cylindrical, triangular, or have an irregular shape may be subject to additional handling charges. This is because such packages are difficult to handle and may require special equipment or handling procedures. Therefore, it is advisable to check with FedEx or consult their website to determine the specific requirements for your package to avoid any unexpected additional handling charges.

How are FedEx Additional Handling Charges Calculated?

FedEx Additional Handling charges are calculated based on the size and weight of the package and the service type and destination. The charge is a flat fee per package and it varies depending on the shipping zone, as determined by the origin and destination of the package. For example, the current FedEx Ground Additional Handling charge for packages that exceed 70 pounds or 108 inches in length is $16.50 per package within the contiguous U.S., while the charge for packages that exceed 130 inches in length is $575 per package. The current FedEx Express Additional Handling charge for packages that exceed 150 pounds or 119 inches in length is $160 per package for shipments within the U.S. and Canada, while the charge for packages that exceed 130 inches in length is $825 per package. These charges are subject to change and may vary based on the fuel surcharge and other factors.

It is important to note that FedEx Additional Handling charges are in addition to the regular shipping fees. These charges are applied to packages that require special handling due to their size, weight, or shape. This includes packages that are not fully encased in cardboard, packages with irregular shapes, and packages that require additional labeling or marking.

Customers can avoid these additional charges by ensuring that their packages meet the size and weight requirements for their chosen shipping service. They can also use FedEx packaging materials, which are designed to meet the requirements for safe and secure shipping. Additionally, customers can choose to use FedEx Freight services for larger or heavier packages, which are designed to handle these types of shipments and may have different pricing structures.

Understanding the Dimensions and Weight Limits for FedEx Packages

FedEx has specific size and weight limits for packages that vary by service type and destination. For example, FedEx Ground has a maximum weight limit of 150 pounds and a maximum length limit of 108 inches for packages shipped within the contiguous U.S. FedEx Express has a maximum weight limit of 150 pounds and a maximum length limit of 119 inches for packages shipped within the U.S. and Canada. It is also important to note that packages that exceed certain dimensions and weight limits may require additional handling, such as freight shipping or special handling.

Tips for Avoiding FedEx Additional Handling Fees

There are several tips and best practices that can help you avoid FedEx Additional Handling fees and reduce your shipping costs. First, measure and weigh your packages accurately and label them properly with the correct weight and dimensions. Second, use the right type of packaging materials and techniques to protect your items and prevent damage during transit. Third, use the most appropriate service level and carrier for your shipment, based on the size, weight, and destination of the package, and compare rates and discounts offered by different carriers. Fourth, consider using a freight broker or consolidator to combine your shipments and reduce your overall shipping costs. Fifth, negotiate rates and contracts with FedEx if you have high shipping volume or require customized services.

The Impact of FedEx Additional Handling on Shipping Costs

The impact of FedEx Additional Handling on shipping costs can be significant, especially for businesses that ship large or heavy items frequently. For example, a $16.50 Additional Handling fee may seem small for a single package, but it can add up quickly with multiple shipments. To illustrate this, consider a scenario where a business ships twenty large packages per week with FedEx Ground, and ten of them require Additional Handling due to their size or weight. This would result in a weekly Additional Handling cost of $330, or $17,160 per year, on top of the regular shipping fees. This cost could be reduced or eliminated by using alternative carriers or shipping methods, or by optimizing the packaging and labeling process.

Common Mistakes that Lead to FedEx Additional Handling Fees

There are several common mistakes that businesses make that can lead to FedEx Additional Handling fees. These include underestimating the weight or size of the package, using weak or inadequate packaging materials, not labeling the package properly, failing to follow the hazardous materials regulations, and shipping fragile or valuable items without adequate protection. To avoid these mistakes, it is important to train your staff on the proper packaging and shipping procedures, to use quality packaging materials and methods, and to double-check the weight and dimensions of the package before shipping it.

How to Properly Measure and Label Large Packages for Shipping with FedEx

To properly measure and label large packages for shipping with FedEx, follow these steps:

  1. Measure the length, width, and height of the package in inches, using a tape measure or ruler. Round up to the nearest whole inch.
  2. Add the three dimensions together to get the sum of the length, width, and height. This is the package's girth.
  3. If the package weighs more than 70 pounds and/or has a girth greater than 165 inches, apply the FedEx Additional Handling label to the package and include the Additional Handling charge in the shipping cost calculation.
  4. Label the package clearly with the correct weight, dimensions, and shipping label, and ensure that it is securely packed and protected with the appropriate materials.

Best Practices for Packing Large Items to Avoid Additional Handling Charges

Some best practices for packing large items to avoid additional handling charges include:

  • Use sturdy, double-walled cardboard boxes or crates that can support the weight and size of the item.
  • Use internal cushioning and padding materials, such as bubble wrap, foam, or peanuts, to protect the item from shocks and vibrations during transit.
  • Use proper strapping and banding techniques to secure the item inside the box or crate, and to prevent it from shifting or moving inside the package.
  • Use warning labels and special handling instructions for fragile or hazardous items.

How to Appeal or Dispute a FedEx Additional Handling Charge

If you believe that a FedEx Additional Handling charge has been applied incorrectly or unfairly to your shipment, you can appeal or dispute it by contacting FedEx customer service and providing evidence to support your case. You may need to provide documentation such as the package weight and dimensions, the shipping label, the invoice, and any other relevant information. It is important to act quickly and to keep all records and communications related to the dispute.

Understanding the Differences Between FedEx Ground and Express Shipping and Their Policies on Additional Handling Fees

FedEx Ground and Express are two different service types offered by FedEx, with different delivery times, coverage areas, and pricing structures. FedEx Ground is a non-guaranteed service that delivers packages within 1-7 business days, depending on the destination. FedEx Express is a guaranteed service that offers same-day, next-day, or 2-day delivery, depending on the service type and destination. The policies on Additional Handling fees also vary between these service types. For example, FedEx Ground imposes a $16.50 Additional Handling fee for packages that weigh more than 70 pounds or that have a girth greater than 108 inches, while FedEx Express imposes a $160 Additional Handling fee for packages that weigh more than 150 pounds or that have a length greater than 119 inches. It is important to check the specific policies and fees for each service type when shipping large or heavy packages with FedEx.

Comparing FedEx's Additional Handling Fees to Other Major Carriers in the Shipping Industry

FedEx is not the only shipping company that imposes additional handling fees on large or oversized packages. Other major carriers such as UPS and USPS also have similar policies and fees, with varying size and weight limits and surcharges. For example, UPS imposes an Additional Handling fee of $16.50 for packages that weigh more than 70 pounds or that exceed certain length, width, or height limits, while USPS imposes a Large Package Surcharge for packages that exceed certain length and girth combined or that weigh more than 70 pounds. It is important to compare the rates and policies of different carriers when shipping large or heavy packages and to choose the most cost-effective and reliable option for your business needs.

About the Author

Anthony Robinson is the CEO of ShipScience, a pioneering company dedicated to helping e-commerce leaders optimize their shipping decisions, reduce costs, and automate tedious processes. With a Bachelor of Science in Economics from Stanford University, Anthony brings over a decade of expertise in logistics, business development, and operational efficiency to the table.

Since founding ShipScience in 2018, Anthony has empowered numerous e-commerce businesses to navigate the complexities of parcel shipping through data-driven insights and innovative solutions. His leadership extends beyond ShipScience, having established Refund Geeks and served on advisory boards at Ciye and RESA Power, showcasing his commitment to driving corporate growth and enhancing operational strategies.

Anthony is passionate about leveraging technology to streamline supply chains and improve customer experiences in the last mile. When he’s not strategizing shipping solutions, he enjoys connecting with industry leaders and staying ahead of the latest trends in e-commerce and logistics.

Connect with Anthony on LinkedIn to learn more about his work and insights on optimizing shipping for e-commerce businesses.

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