A Comparison of Major Carriers’ Weight Limits in Canada: A Complete Guide

Every carrier has its own rules and restrictions for package weight and size, which can impact your shipping costs and logistics. When carrier weight limits vary widely, shipping for your Canadian e-commerce business can become quite challenging.

Failing to understand these weight rules may increase costs and damage your goods. It can also lead to dissatisfied customers, ultimately harming your business reputation and bottom line.

This guide breaks down the weight limits for major carriers operating in Canada to help you ship smarter and keep things running smoothly.

Canada Post Weight and Size Limits 

Canada Post has defined weight and size limits to ensure reliable and cost-effective shipping. Following these guidelines helps your packages move smoothly through their network. Here are the details.

Domestic Shipments:

• The Canada Post maximum weight limit for domestic shipments is 30 kg (66 lbs) per parcel.
• In terms of length, the parcel can be up to 2 meters (78.7 inches) long.
• Similarly, the width of the parcel can be up to 2 meters (78.7 inches).
• The height must not exceed 2 meters (78.7 inches).
• Finally, the combined length and girth of the parcel must be within 3 meters (118 inches).

International Shipments:

Parcels can generally weigh up to 30 kg (66 lbs), which is the Canada Post max weight. However, some destinations may have lower weight limits. So, check the International Destination Listing for accurate details.

• Regarding length, parcels can be up to 1.5 meters (59 inches).
• Similarly, the width of the parcel can measure up to 1.5 meters (59 inches).
• The height is limited to 1.5 meters (59 inches).
• Finally, the combined length and girth must not exceed 3 meters (118 inches).

Additional Considerations:

Oversize Items: Packages exceeding 1 meter (39.4 inches) on any side or over 76 cm (30 inches) on the second-longest side are classified as oversized and may incur additional surcharges based on the Canada Post maximum weight.

Out-of-Spec Items: Packages that significantly exceed the size or  Canada Post max weight limits may face surcharges, a rejected shipment, or have it sent right back to you.

Purolator Weight and Size Limits

Knowing the Purolator weight limit Canada and size restrictions helps avoid delays and extra fees. Here’s what you need to know about Purolator’s standards:

Maximum Weight and Size Limits:

Weight limit: The Purolator weight limit Canada allowance is 150 lbs (68 kg), which is the Purolator maximum weight for each package.

Length: The longest side of your package can’t be more than 108 inches (274 cm).

Girth: The total girth of the package (2 times the width plus 2 times the height) and its length should not exceed 165 inches (419 cm).

Special Handling Considerations:

Oversized Packages: Special handling surcharges apply if your package weighs more than 50 lbs (22.68 kg) or is longer than 48 inches (121.92 cm).

Over Maximum Limit: If your package is over 150 lbs (68 kg), longer than 108 inches (274 cm), or has a combined length and girth over 165 inches (419 cm), it is considered over the Purolator maximum weight limit and may cost you more or be refused for shipment.

Packaging Guidelines:

Box Strength: Use boxes with a minimum edge crush test (ECT) value of 32 lbs/inch or a bursting test of 200 lbs/sq. inch.

Weight Distribution: The contents’ weight should not exceed 50% of the gross weight limit shown on the Manufacturer’s Certification Stamp on the box.

UPS Weight and Size Limits

UPS provides clear weight and size limits to optimize its logistics network. Adhering to the UPS weight limit and other rules ensures hassle-free shipping and avoids unnecessary charges. Here’s an overview of UPS weight and size guidelines:

Maximum Weight and Size Limits:

Weight Limit: The UPS weight limit is 150 lbs (68 kg), and the maximum weight is for individual packages.

Maximum Length: The longest side of your package can be up to 108 inches (274 cm).

Combined Length and Girth: Add the length, twice the width, and twice the height. Ensure it all adds up to 165 inches (419 cm) or less.

Special Handling Considerations:

Large Package Surcharge: If your package’s combined length and girth are over 130 inches (330 cm) or longer than 96 inches (244 cm), you’ll get hit with a Large Package Surcharge. You’ll be subject to a Large Package Surcharge and a minimum billable weight of 90 pounds (41 kilograms)

Over Maximum Limits: If your package weighs more than 150 lbs (68 kg), is longer than 108 inches (274 cm), or has a combined length and girth over 165 inches (419 cm), it will face additional fees under the UPS maximum weight policy.

Heavy Package Sticker:  If your package weighs more than 70 lbs (31.5 kg), you’ll need a special “heavy package” sticker to alert handlers of the additional weight.

Packaging Guidelines:

Box strength: To ensure your box is strong enough to handle the weight, use a sturdy, corrugated box.

Sealing: Seal the package properly by taping up all the seams with durable packing tape.

Cushioning: Protect your package by adding enough padding to stop it from moving around or getting damaged.

FedEx Weight and Size Limits

FedEx sets precise weight and size limits to streamline shipping and prevent additional costs. Understanding these guidelines ensures your shipments comply and reach their destination efficiently. Here’s what you need to know about FedEx’s rules:

Maximum Weight and Size Limits:

Maximum Limit: Your package can weigh up to 150 lbs (68 kg), the FedEx weight limit and FedEx maximum weight.

Maximum Length: The longest side of your package can’t be more than 108 inches (274 cm).

When you add the length plus two times the width and two times the height, the total must be 165 inches (419 cm) or less.

Dimensional Weight Considerations:

To calculate the dimensional weight, multiply your package’s length, width, and height (in inches) by 139, then divide by 139 to get the weight in pounds.

Oversized Packages:

Your package is oversized if it is longer than 96 inches (243 cm) or its length plus girth is more than 130 inches (330 cm). Ensure it adheres to the FedEx maximum weight rules.

Packaging Guidelines:

Box Durability: Use a strong, undamaged corrugated box with all its flaps in place.

How to Seal: When sealing it, cover the flaps and seams with pressure-sensitive plastic tape and H-taping.

Proper Cushioning: Wrap each item separately and put them in the middle of the box, away from the sides, corners, top, and bottom.

DHL Weight and Size Limits

DHL is a trusted global carrier with clear weight and size restrictions for efficient shipping. Knowing these limits helps you avoid extra fees and ensures smooth delivery. Here’s what you need to know about DHL’s guidelines:

Maximum Weight and Size Limits:

Maximum Limit: The DHL weight limit allows each package to have a maximum weight of 70 kg (154 lbs).

Maximum Length: The package’s longest side can be up to 120 cm (47.2 inches).

The package’s width and height can be up to 80 cm (31.5 inches).

Dimensional Weight Considerations:

DHL calculates shipping costs based on whichever is higher:  the actual weight or the dimensional weight.

To determine the dimensional weight, multiply the package’s length, width, and height in centimeters, then divide by 5,000 to get the dimensional weight in kilograms.

Oversized Packages:

If your package exceeds standard dimensions or weight, you may have to pay extra fees or need special shipping arrangements.

Carriers classify items as oversized if they exceed 120 cm in length or weigh more than 70 kg, which can lead to extra fees or special handling requirements.

Packaging Guidelines:

Sturdy box: Use a firm, undamaged corrugated box to keep all the box flaps intact.

Sealing technique: Seal it up by putting pressure-sensitive plastic tape across the flaps and seams in an H-shape.

Cushioning: Wrap each item with padding and place them in the center of the box, away from the sides, corners, top, and bottom.

Comparative Analysis of Carrier Weight Limits

Carrier	Max Weight (lbs)	Max Length (in)	Max Girth (in)	Oversize Surcharge
Canada Post	66	78.7	118	Over 1m in any dimension
Purolator	150	108.0	165	Over 50 lbs or 48 inches
UPS	150	108.0	165	Over 96 inches in length or 130 inches combined
FedEx	150	108.0	165	Over 96 inches in length or 130 inches combined
DHL	154	47.2	118	Over 47.2 inches in length or 79 kg

Maximum Weight Limits

• The maximum weight limits across carriers vary, with Canada Post offering the lowest at 66 lbs. This restriction aligns with the Canada Post weight limit for parcels.
• The DHL weight limit allows up to 154 lbs, making it suitable for heavier shipments.
• Purolator, UPS, and FedEx cap their weight limits at 150 lbs, which aligns with the Purolator weight limit, UPS weight limit, and FedEx weight limit for shipments. This threshold balances flexibility and standardization for most shipping needs.

Maximum Length Limits

• Canada Post supports packages up to 78.7 inches, catering to moderately sized shipments.
• Purolator, UPS, and FedEx allow 108 inches, which accommodates larger items.
• DHL permits a maximum length of only 47.2 inches, which may limit its use for long items but is ideal for compact shipments.

Maximum Girth Limits

• Canada Post and DHL limit girth to a smaller range, making them ideal for standard-sized parcels.
• Purolator, UPS, and FedEx provide more generous girth allowances, offering greater flexibility for bulkier shipments.

Oversize Surcharges

• Canada Post imposes surcharges for any parcel that exceeds 1 meter in any dimension.
• Purolator applies surcharges for packages weighing over 50 lbs or exceeding 48 inches in length.
• UPS and FedEx impose surcharges for packages longer than 96 inches or with a combined length and girth exceeding 130 inches.
• DHL applies surcharges for items over 47.2 inches (120 cm) in length or weighing more than 70 kg (154 lbs).

In short, different carriers are suitable for different shipping needs. For a deeper comparison, discover the top shipping carriers from Canada to the US. Depending on your requirements, choose one that best suits the size and weight of your shipments.

Understanding Dimensional Weight and Its Impact

Dimensional (DIM) weight is how carriers decide shipping costs based on package size, not just weight. It’s a way to charge fairly for lightweight but bulky items that take up a lot of space. 

How to Calculate DIM Weight 

Carriers determine DIM weight using the formula:

DIM Weight=Length×Width×Height ÷ DIM Factor

Length, Width, and Height: These are the outside measurements of the package. Round up each number to the nearest whole number. They reflect the package’s volume, showing how much space it takes up.

DIM Factor: This is a number or divisor the carrier sets that converts the volume into a weight for pricing.  Each carrier uses a different number depending on the service.

Carrier-Specific DIM Factors:

Each carrier uses unique DIM factors to calculate shipping costs. DIM factors may vary based on the type of service, such as:

• Ground shipping: Typically less strict on space than air shipping.
• Air shipping: Often has tighter DIM factor calculations due to space limitations.

The destination also affects DIM factors:

• Domestic shipments: Usually have more lenient DIM factors.
• International shipments: Tend to prioritize space efficiency, leading to stricter DIM factors.

Impact of DIM on Shipping Costs: 

Shipping costs depend on whether a package’s actual or DIM weight is higher. Carriers charge for the larger value to ensure the shipping fees accurately match the space the package takes up, especially for lightweight but bulky items.

How to Calculate and Estimate Weight? 

Understanding DIM Weight Calculations

DIM weight, or dimensional weight, is how carriers calculate shipping costs based on the space a package takes up, not just its weight. DIM is one of the main factors affecting shipping costs, and you calculate it as follows: 

Carrier Name: (Length × Width × Height) ÷ DIM Factor

• Length, Width, Height: Measure the package dimensions in inches or centimeters, rounding each to the nearest whole number.

• DIM Factor: A divisor set by the carrier, representing the volume per unit of weight.

Carrier-Specific DIM Calculations:

The DIM factor varies depending on the carrier and service type, directly affecting how you calculate the dimensional weight. Each carrier has specific formulas and DIM factors to calculate dimensional weight. Here are the general DIM weight formulas that major carriers use:

Canada Post

DIM Weight (kg)=Length (cm)×Width (cm)×Height (cm)​ ÷ 6000

Purolator

DIM Weight (lbs)=Length (in)×Width (in)×Height (in)÷ 1728​×10 (Ground)

DIM Weight (lbs)=Length (in)×Width (in)×Height (in)÷ 1728​×15 (Air)

UPS

DIM Weight (lbs)=Length (in)×Width (in)×Height (in)​ ÷ 166 (Ground)

DIM Weight (lbs)=Length (in)×Width (in)×Height (in)​ ÷ 139 (Air)

FedEx

DIM Weight (lbs)=Length (in)×Width (in)×Height (in)​ ÷ 166

DHL

DIM Weight (lbs)=Length (in)×Width (in)×Height (in)​ ÷ 5000

Remember that carriers like Purolator and UPS use different DIM factors for ground and air shipping. DHL uses a stricter DIM factor, so it’s important to understand how this impacts international shipping. Always check the carrier’s guidelines for accurate calculations.

Tips for Managing Oversized and Overweight Shipments

Handling oversized and overweight shipments requires planning to save money and comply with the carrier’s rules. Here are some tips to help you out:

Know the Carrier Rules and Fees

Every carrier defines oversized or overweight and usually charges extra fees for packages that exceed specific size or weight limits. For example, UPS charges fees if a package exceeds a particular size or weight limit.

Optimize Packaging

Use sturdy, well-sized boxes that fit your items snugly to avoid extra space. For heavy items, use new, strong boxes. Avoid overpacking, as too much packaging can make your package larger and heavier, leading to higher shipping fees.

Consider Freight Services

Less-than-truckload (LTL) Freight is perfect for shipments that don’t require a whole truck. It saves money by allowing you to share truck space with other shipments. Full-truckload (FTL) Freight works best for big shipments that take up a whole truck. It offers direct transport and can get your packages delivered faster.

Negotiate with Carriers

Building a good relationship with carriers can Be a valuable strategy for scoring better rates for oversized shipments, especially if your business regularly ships large volumes.

Use Regional Carriers

Regional carriers often offer better rates for oversized items than national carriers if you ship within specific areas. This (noun) makes them a cost-effective alternative to national carriers for localized shipments. 

Plan Shipping Schedules

Being flexible with your shipping schedule can save you money. You can choose cheaper options, such as deferred delivery services, instead of expensive expedited services.

Be Aware of Regulations

Follow the rules and guidelines for shipping oversized items locally and internationally. This compliance ensures a smooth delivery process while avoiding unnecessary fines, delays, or complications. 

Conclusion

In summary, understanding the size and weight limits for Canada Post, Purolator, UPS, FedEx, and DHL is essential for keeping shipping costs low and avoiding unexpected charges. Accurate measurements, a clear understanding of dimensional weight, and choosing the right packaging are crucial steps to streamline your shipping process.

With a clear understanding of these factors, you can avoid unnecessary fees and make informed decisions for efficient shipping.

Take control of your shipping strategy today- choose a carrier that helps you reduce costs and ship like a pro.

FAQs  

1. Are there standard weight limits for domestic and international shipments?

Each carrier has specific weight limits for shipping and international shipping. For example, Canada Post allows up to 66 lbs (30 kg) for domestic shipping. UPS, FedEx, and Purolator permit packages up to 150 lbs (68 kg). DHL allows up to 154 lbs (70 kg). Weight limits for international shipping vary by destination, so verify them based on your shipment’s destination.  

2. How do carriers determine the maximum weight and size limits?

Carriers set weight and size limits based on safety rules, equipment, and transportation methods. For example, UPS sets a maximum length of 108 inches (274 cm) and a combined length plus girth of 165 inches (419 cm) to ensure efficient handling and transportation. These limits make handling easier, protect carrier staff, and optimize space during transportation.

3. Are there additional fees for overweight or oversized packages with these carriers?

Yes, carriers charge extra fees for packages that exceed standard weight and size limits. For example, UPS and FedEx add large package surcharges for packages longer than 96 inches or with a girth of 130 inches. These surcharges ensure proper handling of big shipments and cover the extra resources needed to ship them.

4. How can I calculate the dimensional weight for my packages?

You can calculate the dimensional (DIM) weight by multiplying the package’s length, width, and height by dividing by a standard divisor. However, this divisor is different for each carrier and can depend on the type of shipping, such as ground or air. Thus, the DIM weight and shipping costs can change depending on your chosen carrier.

5. How can I minimize shipping costs related to package size and weight?

First, choose boxes that aren’t too big for your items to avoid extra fees. Then, minimize packing materials to keep dimensional weight low. If you are a frequent shipper, try negotiating better rates with carriers, as frequent shippers get better deals. Always compare different carriers to find the best rates for your package’s sizes and weight.

6. What are the consequences of exceeding a carrier’s weight or size restrictions?

Exceeding the weight or size limits means extra fees or penalties for your package. The carrier may also ship a package if it’s too big or heavy. Carriers spend more time handling oversized packages, which can cause delays. Excessive size or weight can also lead to improper handling, potentially damaging your package.