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UPS Large Package Surcharge Overview

 This article explains how the UPS Large Package Surcharge works, when it is applied, and how ShipperHQ configurations such as Dimensional Packing and Packing Rules can help prevent it.

When UPS Applies the Large Package Surcharge

UPS applies the Large Package Surcharge when either of the following conditions is met:

  • The actual weight of a package exceeds 110 lb

  • The package dimensions exceed UPS maximum size thresholds, calculated using length and girth

UPS determines this automatically during rate calculation and may apply the surcharge even if dimensional data is incomplete or estimated.

How UPS Calculates Package Size

UPS evaluates package size using the following formula:

Length + (2 × Width) + (2 × Height)

If this calculation exceeds UPS size limits, the shipment may be treated as a Large Package regardless of weight.

Impact on Shipping Costs

The Large Package Surcharge is a flat surcharge per package and can add a substantial cost to the shipment total. If multiple packages are flagged, the surcharge may be applied more than once.

Because UPS applies this logic at the carrier level, ShipperHQ passes the rate through exactly as returned by UPS.

Why Large Package Surcharges Appear Unexpectedly

Large Package Surcharges commonly appear when:

  • Dimensional Packing is not enabled for the carrier being used

  • Packing Rules are configured but not triggered

  • The UPS carrier default Max Per Package Weight of 150 lb causes shipments to be split into fewer, heavier packages when Allow Products to Be Split Across Boxes During Packing is enabled.

In these scenarios, UPS may consolidate weight into a single package that exceeds the 110 lb threshold.

Preventing Large Package Surcharges with ShipperHQ

Enable Dimensional Packing

Dimensional Packing allows ShipperHQ to calculate realistic package sizes and weights before requesting rates from UPS.

Best practices:

  • Enable Dimensional Packing for all UPS carriers tied to your shipping origins

  • Ensure products have accurate dimensions and weights

Use Packing Rules Effectively

Packing Rules such as Pack Separately or Max Weight Per Box help control how items are split into packages.

For example:

  • Splitting products into multiple boxes under 110 lb each

  • Preventing UPS from defaulting to a single heavy package

Packing Rules only apply when Dimensional Packing is active for the carrier used in the rate request.

Key Takeaways

  • UPS applies the Large Package Surcharge when a package exceeds weight or size thresholds

  • The surcharge is applied automatically by UPS and included in the returned rate

  • Proper Dimensional Packing and Packing Rule configuration in ShipperHQ can prevent Large Package charges

Related ShipperHQ Features

For assistance reviewing your configuration or validating package logic, contact ShipperHQ Support.