When ordering items online and having them shipped to your home, the size of the parcel box the item arrives in can vary greatly depending on the size of the item. Smaller items may come in padded envelopes or very small boxes, while larger items can arrive in quite sizable boxes. So what actually is the biggest parcel box that can be used for shipping consumer items?
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Parcel Box Sizes
Parcel boxes come in a variety of standard sizes, from small to extra-large. Here are some common parcel box sizes:
| Small | Approximately 10″ x 7″ x 6″ |
| Medium | Approximately 14″ x 11″ x 6″ |
| Large | Approximately 18″ x 14″ x 8″ |
| Extra Large | Approximately 24″ x 16″ x 12″ |
As you can see, the dimensions increase with each standard parcel box size. But sometimes even these extra large boxes are not big enough for very large or oddly-shaped items. So special oversized boxes are available when needed.
Oversized Parcel Boxes
When an item is too big to fit into even the extra-large 24″ x 16″ x 12″ box, oversized options are used. There are a few standards for oversized parcel boxes:
1. Large Oversized Boxes
These measure approximately 36″ x 24″ x 24″. With over three feet in each dimension, this allows quite large items to be shipped. Items that require this size box include some furniture items, large appliances like refrigerators, and other large household items or equipment. Even though the contents may be heavy, the large dimensions help spread out the weight reasonably.
2. Extra Large Oversized Boxes
For even bigger items, extra large oversize boxes are available measuring roughly 48″ x 24″ x 24″. This four foot length along with the two foot width and height allows for sizable shipments. Items shipped in these boxes can include bookcases, bulky furniture, or other specialty large items. These boxes help keep the heaviest weight close to the ground for safer handling.
3. Oversize Pallet Boxes
The biggest boxes used for regular parcel shipping are oversize pallet boxes. These boxes cover a standard 40″ x 48″ pallet footprint. The height of the boxes can vary by company and use-case, but are commonly 48″, 60″, or 72″.
Here is an example of dimensions for an oversize pallet box:
| Length | 48″ |
| Width | 40″ |
| Height | 72″ |
A box this size allows for couches, mattresses, treadmills, and other extremely large items to be shipped. The pallet footprint ensures stability and standard sizing to work with shipping conveyances and equipment. The taller heights enable bulky furniture or stacked goods to be shipped.
Other Oversized Box Options
In some cases, even more irregular or oversized boxes are required:
1. Custom Crating
For specialty items like fine art or sculptures, custom wooden crating may be built to properly protect the item. This allows for almost any size or shape. International art shipments, such as between museums, often utilize specialized crates.
2. Freight Shipments
For extremely large, bulky items, freight shipping using semi trucks or shipping containers provides another oversize option. Items like industrial equipment, boats, or stacked pallets of goods can be shipped in this method. This often uses open shipping containers or flatbed trucks rather than closed boxes.
Maximum Box Sizes
So what are the maximum box dimensions available for common parcel shipping? Here are some typical maximum sizes:
| Carrier | Max Length | Max Width | Max Height |
| UPS | 108″ | 89″ | 89″ |
| FedEx | 119″ | 83″ | 84″ |
| USPS | 108″ | 61″ | 36″ |
As you can see, carriers allow boxes up to around 9 feet long for their largest sizes. Width and height are a bit lower but still in the 6 to 7 foot range.
These maximums allow nearly any residential item to be shipped in some type of oversize box. Even whole rooms of furniture or the biggest exercise equipment can be accommodated. Just be aware that for the largest boxes, some assembly may be required to get the item into your home!
Packaging Factors
When selecting an oversized parcel box, the shipper must consider a few factors:
Item Size
The box must be large enough to fit the item securely inside. Measure all dimensions and get as close to a perfect fit as possible.
Item Weight
The box and packaging must be durable enough to support the item weight throughout transit. Additional inner supports, braces, or pallets may be needed for heavier items to distribute the weight.
Shipment Method
The logistics of the chosen shipping method must allow a box of the required size. Outsized boxes often need special routes or handling.
Cost
Larger boxes have higher material and shipping costs. The extra size must provide value, such as enabling the item shipment.
Strength Requirements
Oversized parcel boxes must be built sturdy to withstand the materials handling systems used in shipping. Here are some strength factors:
Stacking
Boxes may be stacked up to six high during warehousing and transit. Stacking strength comes from multi-ply corrugated cardboard construction.
Drops
Despite careful handling, boxes may be dropped from conveyor belts, forklifts, trucks, and other handling systems. Several material layers cushion drops.
Crushing
Large stacking weights or fork trucks can exert crushing forces. Edge protectors help avoid crushing damage.
Vibration
Parcel vehicles encounter constant vibration that can shift contents. Interior braces keep items stationary.
Popular Oversized Boxes
Many retailers sell standard oversized shipping boxes in a variety of sizes. Here are some popular options:
| Supplier | Box Sizes |
| Uline | 96″ x 48″ x 45″ |
| Global Industrial | 96″ x 40″ x 48″ |
| Home Depot | 48″ x 40″ x 64″ |
| Walmart | 80″ x 60″ x 60″ |
| Staples | 72″ x 30″ x 30″ |
These common sizes can handle everything from sofas to industrial equipment. The boxes fold flat for low cost storage and shipping prior to use.
Hazmat Oversized Boxes
When shipping hazardous materials that require special Hazmat packaging, oversized box options are still available. Here are some examples:
Metal Drums
Steel drums from 20 gallon to 55 gallon size can be used for certain types of hazardous liquids or powders. These sturdy metal containers provide secure containment.
Fiberboard Boxes
Extra strong multi-ply fiberboard boxes lined with plastic offer both containment and stacking strength for large quantities of hazardous solids.
Caged Totes
For bulky Hazmat items, large plastic totes can be secured within metal transport cages for protection during shipping.
Freight Containers
Intermodal freight containers designed for Hazmat can securely transport oversized quantities of hazardous goods.
Box Construction Styles
Oversized shipping boxes come in two main construction styles:
RSC (Regular Slotted Container)
This common box type has four side panels, four top flaps, and four bottom flaps. Flaps fit into slots to form the top and bottom. Good stacking strength.
FOL (Full Overlap)
FOL boxes have four side panels but single wide top and bottom flaps that overlap completely. Very strong design ideal for heavy items.
Box Materials
Different materials provide strength while minimizing weight:
Corrugated Cardboard
Layers of corrugated cardboard with liners give excellent cushioning and combine lightness with stack/drop strength. Recyclable.
Wood
Durable plywood or OSB panels can be used for custom crates for art shipping or other specialized cases. Higher cost.
Metal
Steel drums or cases provide the ultimate protection for heavy Hazmat shipping. Heavier weight than cardboard or wood.
Conclusion
When an oversized parcel box is needed for shipping something that won’t fit in a regular large box, many options are available. Standards exist for extra-large boxes up to around 9 feet long to accommodate nearly any residential or commercial item. With sturdy materials like corrugated cardboard and structural designs that allow stacking, these oversize boxes provide a secure shipping solution. They ensure your large or heavy items arrive safely at their destination.