This article explains the key factors that affect air freight, including how aircraft size limits influence what can be loaded, when oversized cargo requires a freighter aircraft, how volumetric weight is calculated, why airlines charge minimum weights, and the main reasons costs, delays and routing differences occur. It also outlines practical steps businesses can take to avoid common air freight mistakes, reduce unexpected charges and choose the most efficient service for their shipments.

---

To help demystify air freight, we sat down with ICE Brisbane Operations Manager, Carol Phipps, who brings more than three decades of hands-on industry experience. Her insights provide essential knowledge for any business moving cargo by air and clarify how working with a quality freight forwarder can make a tangible difference.

Why Accurate Dimensions and Weight Matter in Air Freight

How aircraft size limits what can and can’t be loaded

One of the most important steps when preparing an air freight shipment is providing correct dimensions and weight. While this sounds straightforward, many businesses overlook how crucial this information is.

Air freight capacity is determined primarily by the aircraft itself. Most international air cargo does not ride on a dedicated cargo plane as many believe. Instead, it travels in the belly of a standard passenger aircraft, directly beneath where travellers are seated. What limits this freight section is its height. The belly hold of most aircraft is only around 165 to 167 centimetres high, which means your cargo can be no taller than 160 centimetres to fit safely and efficiently.

Many shippers are surprised by this restriction. When someone advises that 180-centimetre-tall freight cannot travel on a passenger aircraft, it may seem arbitrary unless you understand the physical limitations. It is not about preference; it is simply about the available space in the fuselage.

Accurate dimensions ensure your cargo can be loaded without delay, prevent costly rehandling at airports, and avoid last-minute service changes that impact transit time and cost.

When Cargo Is Too Tall for a Passenger Aircraft

The maximum height allowed in a belly-hold

If your shipment is taller than 160–162 centimetres, there is essentially only one practical option: a freighter aircraft.

Unlike passenger aircraft, freighters have their entire upper deck dedicated to freight. This gives them far greater vertical clearance and the flexibility to move oversize cargo. Freight that cannot physically fit into a passenger belly hold will be loaded onto this upper deck.

But this flexibility comes at a cost. Freighter aircraft generally carry less total cargo weight and do not benefit from the high passenger revenue that subsidises the belly hold of passenger flights. Because of this, freighter air freight rates are typically much higher, and capacity is more limited. The decision to move freight on a freighter should therefore be based on necessity or urgency.

Why a Light Shipment Can Be Charged Like a Heavy One

Why high-demand routes affect your freight cost

Many businesses have had the experience of shipping a small, light item —only to be charged a much higher weight than expected. This often comes down to airline minimum charges and yield management. Airlines have fixed minimums for the revenue needed to justify carrying even the smallest shipment. If your cargo is travelling on a popular route, the airline may charge a much higher pivot or minimum, reflecting what they could have earned from heavier, more profitable freight.

In some cases, airlines may even charge based on several thousand kilograms for a shipment that weighs only a fraction of that, depending on the route’s demand and how much revenue they expect per cubic metre.

For small parcels, this is why courier services often provide better value for low-weight shipments. They operate on different pricing structures designed to move small packages efficiently.

Understanding Volumetric Weight and Chargeable Weight

Why bulky cargo is charged differently than dense cargo

In air freight, the weight used to calculate charges often has nothing to do with the shipment’s actual (dead) weight. Instead, airlines charge based on volumetric weight, also known as chargeable weight.

The standard conversion used by airlines is:

1 cubic metre of space = 167 kilograms of chargeable weight.

This means if your freight is light but bulky —such as foam products, sports equipment, large displays or packaging— it will be charged by the volume it takes up on the aircraft rather than by its physical weight.

This ensures airlines maximise their yield. Dense cargo provides higher revenue per cubic metre, while light, voluminous cargo must be priced accordingly to compensate for the space it occupies.

Understanding this calculation is vital for accurate budgeting, comparing quotes and selecting the right service for your needs.

How ICE Helps Your Air Freight Take Off Smoothly

The value of using the right routing and airline partners

Air freight pricing can vary significantly between carriers, routes and service types. With multiple factors at play—dimensions, volumetric weight, freighter availability, route demand and airline minimums—it’s easy to feel overwhelmed.

ICE’s air freight team is here to take that complexity off your plate.

The best way to ensure you are quoted accurately is simply to provide correct dimensions, correct weight and the correct number of pieces. Once the fundamentals are known, ICE can provide both detailed line-by-line pricing or full door-to-door totals, depending on your preference.

Why Cheapest Isn’t Always Best in Air Freight

How Cheaper Routing Can Increase Damage, Delays and Risk

In air freight, a lower-priced quote can sometimes mask slow transit times, excess handling or multiple transshipment points. These factors significantly increase the risk of damage, loss or pilferage as cargo is moved repeatedly between warehouses and aircraft.

ICE prioritises the fastest and most direct routes wherever possible, even if the freight rate is slightly higher. That approach reduces handling, shortens transit time and improves cargo protection end-to-end.

When comparing quotes, it is important to understand not only the cost but also the service behind the cost. Cheaper rates often involve compromises on routing, handling and visibility. ICE’s approach focuses on quality, reliability and safeguarding your goods from origin to destination (that’s why we also offer cargo insurance).

Speak With Our Air Freight Team

Air freight is a detailed and dynamic space. Aircraft configuration, routing, capacity and pricing can vary daily. The best way to avoid unexpected charges or operational surprises is to partner with a forwarder who understands the fine print and proactively guides you through it.

Some of our air freight specialists have been in the industry for decades. They can confidently provide support and advice at every stage, from quoting to booking to final delivery, ensuring your cargo moves efficiently, safely and with full transparency.

Ready to Air Freight It?

Understanding the fundamentals of air freight—such as aircraft limitations, accurate measurements, volumetric weight, routing choices and airline pricing rules—helps businesses avoid delays, minimise extra costs and choose the most efficient path for their shipments. With the right preparation and guidance, air freight becomes faster, safer and more predictable.

At International Cargo Express, our team provides clear advice, accurate quoting and hands-on support to help you move your cargo with confidence. Whether you ship occasionally or manage regular air freight movements, we can guide you through every step to ensure your goods reach their destination on time and in perfect condition.

Speak with our air freight specialists to get tailored guidance, a transparent quote and expert support for your next shipment: 1300 227 461

---

---

Frequently Asked Questions About Air Freight