[paxys]

There's a reason for it. Package sizes and weight limits are optimized for workers who are going to carry them. So yes in your case the total weight loaded on to the truck or plane may be the same, but loading/unloading 3x40 lb boxes and carrying them to your front porch is very different from doing the same with a single 115 lb box.

Airlines work the same way. 2x50 lb bags cost $30 each. One single 100lb bag has a $200 surcharge.

[Closi]

Usually large items go through an entirely different delivery network because the whole parcel delivery chain will be designed around weight limits - I.E. that weight might not be able to go through the automated sorter, and there is very limited capacity for manual workarounds for individual parcels.

[ortusdux]

I also priced out not using a flat rate box w/ FedEx. They quoted:

- 1 small 40lb box - $260

- 3 small 40lb boxes grouped as one shipment - $750

- 8 small 15lb boxes, one shipment - $840