ShippingCowBest way to ship heavy packages
A 100 lb package has no single cross-country cost, because the carrier, the distance, the box dimensions and the heavy-package surcharges all change it. ShippingCow is a commerce technology company that builds and runs seller-owned stores for brands shipping orders near that weight. Fulfillment for the 50 to 149 lb band is provided by partner warehouses.
How to ship a heavy package
Weigh and measure the packed carton, rounding each side up to the next whole inch.
Pick the mode. Up to 70 lb, USPS, UPS and FedEx are all options. From 71 to 150 lb, UPS or FedEx. Over 150 lb, LTL freight.
Check the size lines. Over 48 in on the longest side or 30 in on the second side adds Additional Handling at UPS and FedEx; over 96 in long or 130 in in length plus girth makes it oversize, billed at a minimum of 90 lb.
Work out the billable weight: the greater of actual weight and length × width × height ÷ the carrier's divisor.
Ship from as close to the customer as you can. The zone multiplies the base rate, and FedEx prices its heavy surcharges by zone too.
Carrier limits for heavy packages (2026)
| Carrier | Max weight | Max size | Where extra charges start |
|---|---|---|---|
| USPS | 70 lb | 130 in length plus girth | Dimensional weight over one cubic foot |
| UPS | 150 lb | 108 in long, 165 in length plus girth | Over 50 lb (Additional Handling); over 110 lb (Large Package) |
| FedEx | 150 lb | 108 in long, 165 in length plus girth | Over 50 lb (Additional Handling) |
Packing a heavy package
Use a carton rated for the weight, fill the voids so the product cannot shift, and fully encase it in corrugated cardboard. At UPS and FedEx, packaging that is not fully encased, or is cylindrical like a drum or pail, triggers Additional Handling on its own.
When a 3PL makes sense
When you ship heavy packages every day, the savings come more from where the stock sits than from which carrier you choose. A 3PL with warehouses on both coasts and in the middle turns long zones into short ones. That is what ShippingCow does for products of 50 to 149 lb.
Sources
| Source | What we took from it |
|---|---|
| USPS parcel size, weight and fee standards | USPS 70 lb and 130 in limits |
| UPS 2026 Tariff and Terms of Service | UPS Additional Handling and Large Package rules, including the 2026 cubic and 110 lb triggers |
| FedEx: shipping large items | FedEx weight and size limits |
| FedEx 2026 surcharge and fee changes | 2026 Additional Handling and Oversize list prices by zone, effective January 5, 2026 |
Rules and list prices as published for 2026, checked on Sep 25, 2026. Carrier contracts change the prices, not the thresholds.
Questions
How much does it cost to ship a 100 lb package across the US? +
There is no single cost; the figure depends on the carrier, the distance, the box dimensions and any surcharges for heavy or large packages. A real quote must be built from your exact box and destination. A 3PL in your weight band can help price and route each order.
Which carrier should I use for a 100 lb box? +
The fitting carrier depends on the destination and the box dimensions, not weight alone, because heavy boxes may carry surcharges. A 3PL that handles the 50 to 149 lb range can route each order to the fitting option. ShippingCow is set up for that weight band.
Does ShippingCow ship 100 lb packages? +
ShippingCow is a commerce technology company that builds and runs seller-owned stores. Fulfillment for heavy parcels in the 50 to 149 lb per box range is provided by partner warehouses, so a 100 lb package sits inside that band.
Where does ShippingCow fulfill from? +
ShippingCow has US warehouse locations in New Jersey, California and Texas. Brands can ask which location fits their inventory and customers.
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