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Created on 01.06
Size and Weight Restrictions for International Air Freight Cargo
To ship things predictably, understand how carriers use size and weight to set prices and rules. This guide covers industry rules and limits from planes and regulations.
We'll explain how things like door size and ULD types affect what fits on regular freighters. Learn why airlines have different pallet rules and how to plan accordingly.
Cargo Air started flying in 1997, using B737 freighters for express, mail, dangerous goods, and large items. We use this setup to turn rules into usable numbers, so planning begins with facts, not guesses.
What “size and weight restrictions” really mean in international air cargo
Knowing weight and size rules helps you avoid issues when tendering and shipping. It also helps planners pick the right packaging and routes to save time and money.
Core terms: gross weight, volumetric weight, and chargeable weight
Gross weight is the actual weight of the loaded item. Use certified scales for accurate measurements.
Volumetric weight uses dimensions to calculate a billable weight. A light but large package might cost more than its actual weight.
Carriers use the higher of the gross or volumetric weight to determine prices.
Why dimensional limits differ by aircraft, airline, and route
Size limits are set by door sizes, height, and how much weight the floor can hold. These things change based on the plane and equipment used.
Airlines might have rules that limit shipments even more. Just because something fits doesn't mean they'll take it. They need to have the right connections, skills, and time.
If a route uses different planes, the smallest one usually decides how things get packed. Also, equipment at the airport can control size.
- Mix dense and bulky items in consolidations to optimize chargeable weight.
- Confirm dimensional factors, piece sizes, and aircraft types early.
- Check station handling gear to avoid rework at the terminal.
Regulatory backbone in the United States: FAA, TSA, and industry bodies
Understanding regulations is key to aligning packaging and station rules with actual handling limits. The FAA controls how planes are certified and flown, setting safety rules for weight, floor loads, and gear approval. Following FAA standards is a must for on-time shipments.
The role of the Cargo Airline Association
The Cargo Airline Association in D.C. speaks for U.S. cargo airlines and those involved. It works with lawmakers to create sensible rules that consider real-world operations.
CAA helps things run smoothly by ensuring everyone follows size and weight rules consistently.
TSA security mandates that affect packaging, screening, and access
To keep things moving smoothly, TSA has rules about screening and checking shippers. These rules can change the way you package things. If you don't plan for things like sealed pallets, breaking down items, or extra screening, your shipment might get held up.
Make sure to check the shipper's status, screening process, and how to get into the place early on so you don't run into any problems when you're ready to send your stuff.
How deregulation shaped modern operations
The 1977 deregulation changed capacity, pricing, and overnight delivery. now Specialized carriers could improve routes, also equipment. This affected size and weight rules. Following the rules is key for timely planning of dimensions and weights.
Global standards that impact your freight: IATA and international policies
Global standards help make international shipping more consistent. The IATA rulebook unifies definitions for things like billable weight, handling steps, and container specs that companies use for planning and invoicing.
Even with these standards, countries and airlines add their own requirements. This means following a mix of national and airline rules, which can mean extra paperwork or handling. Standard pallet and container sizes cut down on repacking, but when using different types of planes, you often have to plan for the strictest plane on the route. This limits choices, even if your items fit IATA sizes.
Global security programs go with TSA rules. Export and import locations might have different screening methods and paperwork, which means that locations along a route may not operate in the same way.
Practical tip: Align commercial bookings with operational standards early. Confirm which ULD types are available at origin and transit points to avoid last-minute repacking and delays.
Topic | IATA guidance | Local / airline variation | Practical impact |
Chargeable weight | Standard dimensional factors and definitions | Some carriers use different DIM factors | Quotes may change; check early |
ULD sizes | Harmonized pallet and container specs | Station equipment may limit types handled | May require alternate ULDs or repack |
Security screening | Recommended procedures for exports/imports | National programs add checks | Plan lead time and docs per station |
Handling procedures | Standardized labels and loading rules | Operational nuances per airline | Confirm acceptance criteria before booking |
Aircraft limitations that drive what you can ship
The physical limits of an aircraft set clear boundaries for what moves intact and what must be split or repacked.
Main deck door and internal clearance
Cargo Air's B737 freighters have a main deck door that's 86 x 140. Keep in mind that this is the largest possible size for any item you're loading through it.
Also, the inside height and ceiling shape might be smaller than the door itself. So, even if a tall item fits through the door, it could still bump into something inside while you're loading it.
Floor loads and weight distribution
Reinforced floors protect the airframe, but they have rated floor loads. Distribute weight across pallets or containers to avoid concentrated loads that can exceed those ratings.
Main ULD types and position counts
Picking between AAA containers, AEP/AEH, or 88x125 pallets impacts how much space you use and if they're accepted. ULD fit is key to deciding how to pack things.
Always confirm ULD availability and that ground handling gear supports the intended container types. For a quick primer on how transport choices affect cost and timing, see advantages and disadvantages of air freight.
Real-world specs: Boeing 737 freighters and what they can carry
Knowing exact payloads and position counts helps match shipments to the right 737 variant. Below are concise specs to guide booking and packing choices.
B737-300SF
Payload: up to 42,900 lb (19,460 kg).
Positions: eight AAA containers plus two half containers.
Since the main deck door is 86 × 140, you might have to split up or reconfigure bigger items to get them through. The floors are strong and can handle heavy stuff, but try to spread the weight out if you can.
B737-400SF
Payload: up to 47,100 lb (21,364 kg).
Positions: ten 88"×125" pallet positions (AAA in P1–P10) and an AEP/AEH in P11. Ceiling height exceeds 84.5".
Using 88x125 pallets can help fit more boxed items in a container. This might change the final weight you're charged and how much billable weight you have.
B737-800SF
Payload: up to 52,700 lb (23,904 kg).
Positions: eleven 88"×125" AAA full-height units plus one AEP/AEH. Fleet additions occurred in 2024.
The -800SF has more space and can carry heavier loads than older models. This means you can combine more items and potentially lower shipping costs on some routes by avoiding multiple shipments.
Carrier capabilities matter: from ad hoc charters to dangerous goods
Choosing the right operator can turn a complex uplift into a reliable, on-time move.
When to use dedicated operators
If you have tight deadlines, fragile goods, or large items needing to go on the main deck, go with a specialized carrier. They have custom services and reliable procedures at their facilities.
Ad hoc charters and schedule alignment
Ad hoc charters let you set the flight, airport, and ULD mix. They skip fixed schedules and fit a shipment's needs.
Handling dangerous and special goods
DG-experienced operators make documentation checks and packaging proofing faster, cutting rejection risks and boosting tender acceptance.
Outsized loads
For big shipments, choose carriers that share door sizes, confirm floor strength, and have well-trained staff everywhere.
Partner benefits
When companies work with integrator networks, setting up stations becomes more predictable, and handling complicated logistics goes more smoothly.
Option | Best for | Key advantage |
Dedicated carrier | Tight windows, oversized | Known equipment and consistent handling |
Ad hoc charter | Single-move schedule control | Route and ULD flexibility |
Belly space | Routine palletized freight | Lower cost on scheduled services |
Digital booking, visibility, and data security for compliant shipments
Real-time tools help teams quickly secure space and rates, skipping lengthy emails and unexpected rejections. This speeds things up and ensures operations match booking rules and item details.
Real-time bookings and visibility
CargoAi provides real-time capacity, rates, and instant booking confirmations. Users can quickly view pricing, match cargo size with weight, and secure space in minutes. Automated updates and alerts keep everyone informed, which improves sales and communication.
How freight forwarders optimize cargo dimensions and weight
Forwarders can save time and money by checking size and station limits before booking. Doing this avoids repacking, rejected shipments, and delays.
Pre-shipment checks
Verify aircraft type and door dimensions against the largest piece. Make a drawing or photo with measurements to confirm fit and avoid last-minute splitting.
Confirm airline policy differences on max piece weight, battery acceptance, and ULD availability. Policies vary and can change acceptance and packing rules.
Balance dense and volumetric freight in consolidations to optimize chargeable weight. Mix heavier items with bulky parcels to reduce overall billable volume.
Check airport constraints — GSE availability, screening capability, and operating hours affect uplift windows. Some stations lack specific ULDs or high-loaders needed for oversized pieces.
- Use digital tools for schedule comparison and fast rebooking to keep operations flexible.
- Keep a short checklist with aircraft door, max piece weight, and screening method at origin.
"Proactive checks are the single best way to protect schedules and reduce surprise costs."
Special cargo and dangerous goods: policy, safety, and documentation
Moving dangerous or big shipments usually depends on following specific rules and doing the paperwork right. Cargo Air deals with these types of shipments and offers safety and security contacts for help.
Getting your shipment accepted depends on the airline's rules, the station's ability to handle it, and having the correct paperwork, packaging, and labels that meet all the rules.
When carriers accept regulated shipments
Carriers verify classification and may refuse items that lack proper labels or documentation. Stations with limited screening or no reinforced floors can also block acceptance.
- Shippers must classify, declare, and provide emergency response info.
- Carriers check acceptance, ensure segregation, and confirm handling procedures.
- Specialist companies offer packing, documentation, and DG consulting to lower refusal risk.
Practical steps to reduce delays
Get in touch with the operator's safety and security teams early on. Send over emergency contact info and shipper declarations well before you make an offer.
Book early to allow time for approvals and any airport or airline permits required.
Role | What to provide | Operational impact |
Shipper | Proper classification, labels, SDS, ERI | Faster acceptance; fewer rejections |
Carrier | Acceptance confirmation, segregation plan | Safe handling and compliant uplift |
Specialist companies | Packing, documentation, compliance checks | Reduced audit and tender risk |
cargo air considerations for U.S. shippers today
For most shippers, current U.S. shipping routes and gear limit what they can do. How easy it is to move stuff depends on the route's traffic, available containers, and station tools. Hubs with special equipment can usually handle bigger packages.
Make sure your shipment size fits the planes on your route. Before guaranteeing delivery dates, double-check door sizes and container compatibility. Checking beforehand can save you money. Match sales promises with what you can realistically handle. This protects your profits and ensures reliable service.
- Narrowbody freighters work well for regional express and e-commerce freight.
- Heavy or outsized loads usually need dedicated widebody options and confirmed reinforced floors.
- Build a preferred-carrier list based on proven performance for similar shipments to lower repeat risk.
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