Learning Center
Master the complexities of shipping surcharges and dimensional weight
Measuring Packages
How do I measure my package correctly?
Width: The second longest side
Height: The shortest side
Always measure to the nearest whole inch. Include any bulges, handles, or irregular protrusions in your measurements.
What if my package is round or cylindrical?
Length: The length of the cylinder
Width & Height: The diameter
Carriers treat cylinders as rectangular boxes with width and height equal to the diameter.
Should I round up or down?
Dimensional Weight
What is dimensional weight?
Formula: (Length × Width × Height) ÷ DIM Divisor
Why do carriers use different DIM divisors?
• UPS: 139 (all services)
• FedEx: 139 (Ground & Express)
• USPS: 166 (zones 5-9 only)
• DHL: 139 (Express)
Lower divisors = higher dimensional weight = higher costs for large, light packages.
When does USPS apply dimensional weight?
Surcharges
What triggers a Large Package Surcharge?
FedEx: Length > 96" OR Length + Girth > 130"
Large Package Surcharges typically start at $135+ and replace dimensional Additional Handling fees.
Do surcharges stack?
Usually Stack: Residential + Fuel + Delivery Area
Don't Stack: Multiple Additional Handling types (only highest applies)
Replaces: Large Package replaces dimensional Additional Handling
Each carrier has specific stacking rules we follow precisely.
What's the difference between Additional Handling types?
• Weight: Package > 50 lbs (FedEx) or > 70 lbs (UPS)
• Dimensions: Any side > 48" or second longest > 30"
• Packaging: Not fully encased in corrugated cardboard
Only the highest Additional Handling fee applies if multiple conditions are met.
Why is my residential package more expensive?
• Lower stop density (fewer packages per neighborhood)
• More attempted deliveries
• Longer distances between stops
Residential surcharges range from $5-6 for most carriers. USPS doesn't charge extra for residential delivery.
Common Mistakes
What mistakes trigger unexpected surcharges?
2. Ignoring irregular shapes: Measure the extremes of odd-shaped items
3. Wrong orientation: Length must be the longest dimension
4. Not checking all services: Ground and Express have different rules
5. Assuming surcharges stack: Some replace others entirely
Why does 1 inch matter so much?
• 48" package = No Additional Handling
• 49" package = $28+ Additional Handling fee
• 105" Length+Girth = No Large Package fee
• 106" Length+Girth = $135+ Large Package Surcharge
That single inch can add significant cost to every shipment.
Using ShippingRulesGuide
How current is your data?
Why do your calculations differ from my invoice?
• Negotiated rates: You may have custom pricing
• Zone-based fees: Some surcharges vary by destination
• Peak surcharges: Temporary fees during high-volume periods
• Measurement disputes: Carriers may measure differently
Our calculations show standard published rates.
Can I save my frequently used package sizes?
Shipping Terms Glossary
Billable Weight
The weight used for pricing - either actual weight or dimensional weight, whichever is greater.
Girth
The measurement around the package: 2 × Width + 2 × Height. Used with length for size limits.
Length + Girth (L+G)
Combined measurement of longest side plus girth. Common threshold for Large Package fees.
Zone
Geographic pricing regions based on distance from origin. Higher zones = greater distance = higher cost.
Cubic Pricing
USPS pricing tier based on volume (cubic feet) rather than weight. Available for high-volume shippers.
Delivery Area Surcharge (DAS)
Extra fee for delivery to less accessible areas. Includes DAS Extended for remote locations.
Peak/Demand Surcharge
Temporary fee during high-volume periods (holidays, peak season) to manage network capacity.
Fuel Surcharge
Variable fee based on fuel prices, updated weekly. Applied as percentage of base transportation charges.
Industry Insights
🤔 Why There's No Zone 1 in UPS & FedEx Shipping
Ever wondered why shipping zones start at Zone 2? It's not a mistake – it's a deliberate business strategy by major carriers to maintain higher profit margins on local deliveries.
What Would Zone 1 Be?
Zone 1 would theoretically cover deliveries within a 0-50 mile radius – essentially local, same-day delivery territory. This is your "across town" or "next city over" type of delivery.
The Business Reality
UPS and FedEx deliberately skip Zone 1 pricing for strategic reasons:
- Profit Protection: Both carriers already make many deliveries within 50 miles and charge Zone 2 rates for them
- Market Positioning: Creating a cheaper Zone 1 would reduce revenue from their existing local delivery business
- Competition Avoidance: They leave the ultra-local market to smaller courier services and gig economy platforms
What This Means for You
When shipping to a nearby location (even just 10-20 miles away), you're paying Zone 2 rates – the same as shipping 100-150 miles. This "Zone 1 gap" is why local courier services and same-day delivery startups can sometimes offer better rates for short-distance shipping.
💡 Pro Tip: For truly local deliveries (under 50 miles), consider comparing rates with local courier services, as they operate in the space that UPS and FedEx have intentionally avoided with their Zone 2 minimum pricing.
Still have questions?
We're here to help you understand shipping surcharges