Sending Oversized or Heavy Parcels
Every courier has different limits and every courier charges surcharges. Here is how to price oversized parcels properly.
Quick Price Check
Enter your postcodes to see live prices from 20+ couriers.
Once a parcel goes beyond the standard small-parcel envelope, pricing gets complicated. Couriers apply dimensional limits, weight limits, girth limits and volumetric calculations, any of which can turn a £8 parcel into a £40 one. Understanding the rules before you book saves real money.
Maximum limits by courier
| Courier | Max weight | Max length | Max length + girth |
|---|---|---|---|
| Royal Mail | 20kg | 61cm | 104cm |
| Evri | 15kg | 120cm | 245cm |
| Yodel | 30kg | 150cm | 300cm |
| DPD | 31.5kg | 175cm | 300cm |
| Parcelforce | 30kg | 150cm | 300cm |
| Pallet networks | 1,000kg+ | 2.4m | n/a |
Volumetric weight: the hidden cost
Couriers charge on whichever is greater — actual weight or volumetric weight. The formula is:
A 60 x 40 x 40cm box weighing 5kg has a volumetric weight of 19.2kg — so you pay the 20kg price even though it only actually weighs 5kg. This is why bulky-but-light items like pillows, lampshades and packaging materials are expensive to ship.
Some couriers use a divisor of 4000 or 6000 instead of 5000. Royal Mail Tracked uses actual weight only, which is why it wins on light, bulky parcels under 2kg.
Surcharges you did not expect
- Oversize surcharge: £15–£25 if your parcel exceeds the standard envelope even slightly.
- Over-length surcharge: Applied when one side is above a threshold (commonly 120cm).
- Two-person handling: £10–£20 for parcels over 25kg that cannot be lifted by a single driver.
- Remote area surcharge: £8–£25 for Highlands, islands and Northern Ireland on heavy items.
When to switch to pallet delivery
Once you cross 30kg, or dimensions take you outside courier limits, pallet is almost always cheaper than a courier. A mini quarter pallet (up to 250kg, 60 x 80 x 80cm) typically costs £35–£50 next-day across mainland UK. A full pallet (1,000kg, 120 x 100cm) costs £55–£80.
Providers like Palletways, Palletforce and Pallet Online all have next-day networks. You will need a forklift or tail-lift delivery (+£10–15) at one or both ends.
Best couriers for 20kg+ parcels
- DPD Next Day: best overall for 20–30kg where speed and tracking matter.
- Parcelforce Express 48: cheapest for 25–30kg in the 2-day band.
- Yodel Direct 48: competitive on price for 20–30kg non-urgent.
- Pallet network: anything above 30kg or outside courier dimensions.
Before you book, measure every side and weigh on a proper scale. Dimension disputes add surcharges and delays. Run a comparison with accurate measurements to get the real price.