Girth is the limit people miss
Length plus girth means the longest side added to twice the width plus twice the height. A 40 x 22 x 22 in carton is nowhere near 108 inches long, yet its girth of 88 inches puts it at 128 combined, most of the way to the 165 cap. Lay the tape around the packed box, not the flat one, because a stuffed carton bows outward and hubs measure what arrives.
Two charges sit under the cap
UPS lists a Large Package Surcharge for domestic parcels over 130 combined inches, over 96 inches of length, over 17,280 cubic inches, or heavier than 110 lb, and bills those at a minimum of 90 lb. Additional Handling has its own triggers, among them a longest side over 48 inches, a second-longest side over 30 inches, a cubic size over 10,368 cubic inches, and any package not fully encased in corrugated cardboard. Both lists come from ups.com, checked 2026-07-28, which publishes the triggers without the amounts, so no amount appears here.
The two charges do not stack
In the carrier's own words, an Additional Handling charge will not be assessed when a Large Package Surcharge is applied. That matters when you are deciding whether to shave an inch off a carton: dropping below the large package trigger can land you back in additional handling rather than in the clear, so check both trigger lists before you rebuild the box.