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When I am flying, if I check in the bag, they weigh it and if it's over some specific number (50lbs? Don't remember, but it doesn't matter) they demand I pay ridiculous money for it being overly massive. Unless I, right in front on them, take some stuff out of the checked bag and put it into my carry-on bag, which they know I will be taking with me onboard. Last time we did this dance over 2 pounds. How does it make any sense? I understand carrying more mass takes more fuel, but putting it into my carry-on does not change the mass, and I could be traveling with a box full of lead bricks and nobody would tell me a word if it fits the carry-on size. One could suppose maybe the handlers are not allowed to lift over 50lbs - but if I pay the ridiculous payment, they suddenly become allowed?
I'm not even saying they charge the same for 2 yo kid and for 400lbs landwhale, so clearly the mass is not that important here. Why are they doing it? Just to piss me off because airlines secretly agreed their goal must be to maximize the amount of frustration in the Universe? Or there's some logical reason for it?
My guess would be it's related to machine tolerances, workplace safety laws, or negotiated union limits. For example, workers transferring luggage might have a limit (legal or contractual) where single worker only lifts 50 lbs. Oversize bags probably get tagged and go through a different process. For example, maybe 2 workers lift the oversize bags.
I think this is probably it. In the US the standard is set by the NIOSH Lifting Equation which sets the starting threshold for required two person lift at 51 lbs. The airline probably faces liability if they do not mark bags over 50 lbs as oversized.
From the marginal fuel consumption point of view, most xUS airlines do set a limit on carry-on baggage weight too. Lufthansa for examples sets it at (iirc) 9 kg. They don't normally enforce it, but I have seen people being asked to weight their carry-on baggage after moving items from overweight checked bags on Lufthansa in particular.
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