Michael Turner
Size and weight limits: Major U.S. carriers generally accept parcels as stowed items when linear dimensions (length + width + height) do not exceed 62 inches (157 cm) and gross weight is ≤50 lb (23 kg). Overweight surcharges commonly apply: 51–70 lb ≈ $100, 71–100 lb ≈ $200; items over 100 lb usually require cargo handling and separate booking. Oversize fees for exceeding dimensional limits often fall between $100 and $200. International allowances and fees vary by route and fare class – consult the carrier’s published policy for the specific itinerary.
Packing recommendations: Use a double‑wall corrugated container or a wooden crate, provide 2–4 inches (5–10 cm) of cushioning around all fragile items, fill voids to prevent shifting, reinforce seams and corners with heavy‑duty tape and external strapping, remove prior routing labels, attach a durable ID tag with name and phone number, photograph contents before drop‑off, and pre‑weigh the parcel to avoid surprise charges at the counter.
Battery and hazardous‑goods guidance: Lithium cells and spare batteries are typically prohibited from the aircraft hold and should be carried in the cabin; installed batteries in devices may be allowed but batteries above 100 Wh often require airline approval. Aerosols, flammable liquids, compressed gases and other restricted materials must be declared and may need freight handling or be denied carriage. If uncertain, declare items at ticketing or contact the carrier’s hazardous‑goods desk prior to travel.
Fees and alternatives: Expect economy fares on many U.S. routes to include first‑item fees in the $30–$35 range domestically; oversize and overweight surcharges apply as noted above, and very large or irregular shipments frequently move through cargo tariffs. For high‑value, fragile or bulky parcels consider ground courier or dedicated air cargo services, and purchase supplemental insurance if standard carrier liability limits are insufficient.
At the airport: Present the parcel at the ticketing or cargo counter well before departure, declare fragile or restricted contents, retain the drop‑off receipt and any tracking number, inspect and note preexisting damage on the carrier’s form, and request special handling tags when available.
Stowing a carton as hold baggage on a U.S. carrier
Recommendation: Present parcels at the ticket counter for acceptance into the aircraft hold; ensure each parcel measures no more than 62 linear inches (length + width + height ≤ 158 cm) and weighs 50 lb (23 kg) or less to avoid standard oversize and overweight fees on domestic economy fares.
Packing and protection: Use a double-walled shipping carton or a hard-sided case. Reinforce seams with at least three layers of heavy-duty tape, cushion contents with foam or bubble wrap, and secure loose parts. Photograph each face of the parcel and the packing list before handing it over.
Labeling and documentation: Place the passenger name, contact phone, and itinerary inside and outside the parcel. Add a copy of the boarding pass/ticket inside the package. Attach fragile stickers only if contents are delicate; liability for damage to non-standard containers can be limited.
Weight and size surcharges: Parcels exceeding 50 lb (23 kg) or 62 linear inches (158 cm) typically incur additional charges. Oversize surcharges often begin at the 63–80 in (160–203 cm) range; overweight penalties commonly start at 51–70 lb (23–32 kg). Parcels above carrier-specified hard limits may be refused or require cargo/freight shipping.
Restricted items and batteries: Loose lithium batteries must not be placed inside hold parcels; lithium-ion batteries are preferred in carry-on with terminals taped. Firearms, ammunition, and certain hazardous materials require advance declaration, certified packaging, locked hard cases, and compliance with federal regulations.
When to choose freight instead: For irregular shapes, very heavy items (>70 lb/32 kg depending on route), or valuable fragile goods, arrange freight or courier service instead of acceptance into the aircraft hold to gain tracking, declared value coverage, and specialized handling.
At the airport: Weigh and measure parcels at home and again at the counter. If a parcel triggers an oversize/overweight fee, request a written rate quote before payment. Retain all receipts and the barcode tag photo; file a damage or loss claim within the carrier’s stated deadline if problems occur.
Cardboard and Wooden Containers for Transport in the Aircraft Hold
Corrugated containers and wooden crates are generally permitted in the aircraft hold if they meet the carrier’s size, weight and packing rules; choose a wooden crate for heavy, odd-shaped or highly fragile items and a reinforced corrugated container only for lighter, well-padded contents.
Size, weight and handling thresholds
Keep total linear dimensions (length + width + height) at or below 62 in (157 cm) to avoid oversize classification. Standard permitted piece weight is 50 lb (23 kg); expect overweight surcharges for pieces 51–70 lb (23–32 kg) and higher penalties above 70 lb (32 kg). Items exceeding roughly 80 in (203 cm) linear or 100 lb (45 kg) are commonly redirected to the carrier’s cargo service rather than standard hold transport.
Measure with all external handles, wheels and skids included. Ensure the unit is single-piece and stable; loose components or protrusions often trigger manual handling and may be refused at the airport counter.
Packing, legal and safety requirements
Use heavy-duty corrugated fiberboard, triple-seal seams with wide filament tape, internal bracing and a rigid base (plywood or pallet). For wooden crates, provide full enclosure, internal cushioning, secure fasteners and, for international movements, ISPM 15 heat-treatment/fumigation marking where applicable. Protect corners with edge guards and apply at least two external straps.
Do not place spare lithium batteries, flammable liquids, compressed gases, firearms without proper declaration and packaging, or other hazardous materials in a hold container. Installed batteries may be acceptable if terminals are protected; spare (loose) lithium cells/packs must travel in the cabin or via approved cargo channels. High-value or irreplaceable items are safer carried onboard or shipped using a freight courier with declared value coverage.
Photograph contents and external labeling before handing the unit to the airline, keep receipts, and request any required pre-approval at the airport ticket counter or the carrier’s cargo/acceptance desk. When size, weight or contents approach limits, arrange a cargo booking–this avoids unexpected refusals and better protects oversized or fragile shipments.
Size, weight, and dimensional limits for hold parcels
Adhere to the carrier’s published limits: maximum linear dimension of 62 inches (158 cm) and per-piece mass of 50 lb (23 kg); items that exceed these thresholds will incur surcharges or may need to travel as freight.
How linear dimension is measured
Linear dimension = length + width + height, measured including packing, handles and wheels. Example: 40″ + 18″ + 6″ = 64″ → exceeds the 62″ threshold. Measure along the longest points and report the greater of inches or centimetres if the carrier uses metric.
Weight bands, fees and acceptance limits
Standard acceptance: ≤50 lb (≤23 kg). Overweight band 51–70 lb (23–32 kg) usually carries a surcharge; 71–100 lb (32–45 kg) typically has a higher surcharge and may be restricted to cargo handling. Items over 100 lb (45 kg) are generally not accepted for stowage in the aircraft hold and must be shipped via freight. Always confirm the applicable fees and absolute limits for the specific route and fare.
Practical recommendations: weigh packed parcels with a portable scale; split dense contents into multiple parcels to avoid overweight penalties; use internal cushioning and sturdy packaging but keep overall dimensions within limits; label parcels with contact details and fragile markings. For heavy or bulky aquarium equipment consult gear-size guidance such as best aquarium co2 regulator and consider freight services when weight or dimensions exceed typical hold limits.
Pack, tape, and label a carton to meet carrier requirements
Place fragile items in the center with a minimum of 4 in (10 cm) of cushioning on every side; use bubble wrap, foam sheets, or molded inserts and keep heavy pieces at the base to maintain a low center of gravity.
Materials to have on hand
- Corrugated carton or wooden crate rated for the intended weight
- 3–6 mil bubble wrap, foam sheeting, or crumpled kraft paper
- 2–3 in wide pressure-sensitive packing tape (polypropylene or PVC), plus a tape dispenser
- Reinforcing corner boards and cardboard sheets for layered bracing
- Plastic or metal strapping and a tensioner for heavy parcels
- Printed adhesive shipping labels and a permanent marker
- Clear packing tape to laminate labels, tamper-evident tape optional
Packing and internal protection (step-by-step)
- Line the base with a 1–2 in layer of cushioning. Place the heaviest item flush against the base centered side-to-side.
- Wrap each item individually with at least two layers of bubble wrap; fragile glass or ceramics require double-wrapping and foam corner protection.
- Fill voids with crumpled kraft paper or foam peanuts to prevent movement; items must not shift when the parcel is gently shaken.
- For long or thin items, add internal bracing (cardboard tubes or wooden slats) to prevent bending.
- Place a duplicate label or contact card inside beneath a top layer so contents remain identifiable if outer label is lost.
Do not rely on packing peanuts alone for multi-piece loads; use layered cardboard sheets between levels and corner boards for stacked contents.
Sealing and external reinforcement
- Use the H-taping method: tape along the main seam and both edge seams with 2–3 full width passes.
- Apply at least one continuous wrap of tape around the carton’s girth for extra seam security; reinforce all corners and the lid overlap.
- For parcels over 40–50 lb, add plastic or metal strapping and secure strap ends with seals; strap both lengthwise and crosswise if shape warrants.
- For wooden crates, screw the boards and then tape seams; do not rely on tape alone for structural wood fastenings.
- Use tamper-evident tape where available; avoid thin household tape that tears easily.
Labeling and markings
- Apply a printed address label with full name, daytime phone, and destination airport code; place a duplicate inside.
- Cover the label with clear packing tape or a self-adhesive plastic pouch to protect it from moisture.
- Affix orientation arrows and “FRAGILE” stickers where relevant; place a “THIS SIDE UP” label if internal layout requires a specific orientation.
- Attach any carrier-issued tags or receipts at the ticket counter or drop-off point; secure them with tape so they can’t detach in transit.
Remove or isolate spare lithium batteries: keep them with the passenger in the cabin and tape exposed terminals; devices with installed batteries should be protected against accidental activation. Consider a hard-sided alternative–see best luggage with built in closet–for frequent transport of fragile or high-value items.
How are fees for transported parcels, oversize charges, and special handling applied?
Pay oversize and special-handling surcharges at the ticket counter or bag-drop; fees are assessed per piece and per flight segment after measurement and weighing.
Process used by the carrier:
– At check-in counter or self-service drop, staff measure length + width + height (linear inches) and place the item on a scale. The reservation/PR system then applies a sequence: base piece fee (if not included in fare) → overweight surcharge (if over the weight threshold) → oversize surcharge (if linear inches exceed the limit) → any special-handling charge. Fees stack unless fare rules or status exemptions waive them.
– Exemptions: premium cabin tickets, elite status holders, certain credit-card benefits, active-duty military and some infant/child policies may waive base piece fees or surcharges per the carrier’s fare rules. Proof of eligibility must be presented at ticketing.
– Items exceeding maximum permissible weight or dimensions are typically refused for transport in the aircraft hold and must be forwarded via cargo services. Dangerous goods, high-value fragile items, and some musical instruments require advance approval and may be routed to cargo automatically.
– Special-handling designation is added as a tag code or remark on the baggage record (e.g., FRAGILE, SPORT, MUSICAL). Ground crews follow that tag for manual handling, gate-checking, or oversized-stow procedures; a separate fee may be charged or the item may be treated under the oversize/overweight fee structure.
| Fee type | Typical threshold | Typical charge (U.S. domestic example) | How applied |
|---|---|---|---|
| Base piece fee (first) | Applies when fare does not include a free piece | $30 | Per passenger, per segment; assessed before surcharges |
| Base piece fee (second) | Same as above | $40 | Per passenger, per segment; assessed before surcharges |
| Overweight | 51–70 lb (23–32 kg) | $100 | Added on top of base fee; higher tier for 71–100 lb |
| Overweight (higher tier) | 71–100 lb (32–45 kg) | $200 | Added on top of base fee; items >100 lb usually not accepted for hold |
| Oversize | >62 linear inches (158 cm) | $200 | Added on top of base fee; items >115 linear inches routed to cargo |
| Special handling (sports, musical) | Varies by item and advance notice | May be additional or included under oversize/overweight | Declared at reservation or at counter; tag code placed and manual handling provided |
Practical steps to minimize unexpected charges: measure and weigh the parcel before arriving, consult the carrier’s route-specific baggage policy for fare class exceptions, declare items requiring special handling at booking or by phone, and consider cargo shipment for items that exceed 115 linear inches, weigh over 100 lb, or are especially fragile or valuable.
Prohibited contents for stowed parcels and claim procedure
Do not place hazardous materials, spare lithium batteries, cash, high-value jewelry, fragile irreplaceables, or undeclared firearms in a parcel that will be stowed in the aircraft hold; declare regulated items at the ticket counter and follow locked hard-sided container rules for weapons and packaged ammunition.
Strictly forbidden or restricted items
Explosives and incendiaries: fireworks, flares, blasting caps, gunpowder, flammable aerosols (full cans), and any detonators – absolute ban for carriage in the hold.
Flammable liquids and fuels: gasoline, kerosene, paint thinner, lighter fluid, solvent-based paints; small amounts of consumer aerosols or toiletry aerosols may be allowed if permitted by regulations, but do not rely on this–leave them out.
Compressed gases: oxygen cylinders, scuba tanks (unless properly emptied and approved as cargo), butane, propane cartridges; most compressed gas items are prohibited unless approved through cargo.
Lithium batteries: spare lithium-ion or lithium-metal batteries for phones, cameras, power banks, and accessories must travel in the cabin; devices with installed batteries are generally acceptable in the hold but follow manufacturer watt-hour limits and carrier rules.
Toxic, corrosive, radioactive, and biological agents: bleach, acids, infectious materials, radioactive sources, and similar hazardous chemicals are banned from hold transport.
Valuables and irreplaceables: cash, precious stones, rare artwork, passports, original documents, prescription medications, and essential electronics should remain with the passenger in the cabin, not in stowed parcels.
Live animals and perishable foods: live animals are normally not permitted in the hold except via approved cargo services; perishable foods may spoil and are discouraged unless shipped under proper conditions.
How to file a damage or loss claim
Report immediately: report visible damage or missing contents to the airport service desk before leaving the terminal. If not possible onsite, notify the carrier’s baggage service within 24 hours for domestic itineraries and within 7 days for international itineraries to preserve rights.
Gather evidence: retain the boarding pass, baggage receipt/tag, drop-off receipt, serial numbers, original purchase receipts, and take high-resolution photos of the damaged parcel and packaging. Create an itemized inventory with estimated values.
Submit documentation: file the claim via the carrier’s official web form or customer service email/portal; attach photos, receipts, baggage tag images, and a clear description of loss/damage. Keep claim reference number for follow-up.
Deadlines and timing: if a parcel is delayed and not delivered within 21 days it is commonly treated as permanently lost for settlement purposes; damage reports should be filed within the time windows above. Expect an acknowledgment within a few days and a resolution or request for more information within 30 calendar days in many cases.
Liability and compensation: international carriage may be governed by the Montreal Convention with liability limited to a specified SDR amount (roughly SDR 1,288, approximately USD 1,700 as of 2024); keep receipts to maximize reimbursement. For higher-value items, purchase declared-value coverage or separate shipping insurance before travel.
Escalation and documentation retention: preserve all original documents until the claim is closed. If unsatisfied with the outcome, escalate via the carrier’s formal appeal channel and, if applicable, file a complaint with the U.S. Department of Transportation or the relevant national aviation authority.
Tip: small GPS trackers often contain lithium batteries and may be restricted from the hold–place tracking devices in carry-on when possible; see a recommended model list here: best luggage gps tracker for international travel.
FAQ:
Can I check a cardboard box as checked baggage on American Airlines?
Yes. American Airlines will accept a box as checked baggage provided it meets the carrier’s size and weight limits and does not contain prohibited items. Use a strong, well-sealed box, label it with your name and contact information, and bring it to the check-in counter so staff can assess and tag it.
What are the size and weight limits for a box checked on American Airlines?
For most fares the maximum linear dimensions are 62 inches (length + width + height) and the standard weight limit is 50 lb (23 kg). Bags between 51–70 lb may be subject to an overweight charge; items over 70 lb may not be accepted as regular checked baggage and could require special handling or cargo shipment. International routes and premium cabins can have different allowances, so check the airline’s baggage page for your specific itinerary before you travel.
Will a box be handled differently than a suitcase at the airport?
A box can be routed through the same checked-baggage system as a suitcase, but its shape and construction sometimes cause agents to route it to manual handling or special belts. At some airports a box may not fit self-tag kiosks or automated conveyors, so staff will likely require counter check-in. Fragile contents have no guaranteed special treatment: if the item is fragile, consider protective packing, a hard case, or declaring it at the counter for possible special handling or separate acceptance procedures.
Are there restrictions on packing batteries, electronics or valuables inside a checked box?
Yes. Spare lithium-ion batteries and power banks must be in carry-on baggage and are not acceptable in checked baggage. Devices with installed batteries are generally permitted in checked bags but placing expensive electronics, jewelry, money, passports and other irreplaceable items in checked baggage is not recommended. Flammable liquids, aerosols and other hazardous materials are prohibited or restricted in checked baggage. Check American Airlines’ list of prohibited items before packing.
How should I pack and label a box so it survives baggage handling and can be found if lost?
Use a sturdy, double-walled box and reinforce seams and corners with wide packing tape. Wrap fragile items individually with cushioning material and fill empty spaces to prevent shifting. Place a packing list and a copy of your contact details inside the box as well as a clear external label with name, phone number and destination address. Remove or tape over old shipping labels to avoid confusion. At the check-in counter ask that the box be tagged and request a baggage receipt; consider purchasing travel insurance or checking the carrier’s liability terms for checked items if contents are valuable.
