Double Deep Pallet Racking

Double deep pallet racking stores pallets two-deep on each side of the aisle, effectively doubling storage density while...

Double Deep Pallet Racking

Double deep pallet racking stores pallets two-deep on each side of the aisle, effectively doubling storage density while maintaining reasonable access. This system is ideal for warehouses with medium SKU counts and uses specialized deep-reach forklifts.

Double storage density
Medium SKU optimization
Deep-reach forklift access
Cost-effective solution

Overview

Double deep pallet racking is a high-density storage solution that increases warehouse capacity by storing pallets two deep on each side of the aisle. This effectively doubles the number of pallet positions compared to single-deep selective racking while reducing the number of aisles needed by approximately 50%.

This system strikes an excellent balance between storage density and selectivity, making it ideal for warehouses with a moderate number of SKUs where each SKU has multiple pallets in inventory. While the rear pallet in each pair is not directly accessible (requiring the front pallet to be removed first), the system still provides good stock rotation when managed properly.

Double deep racking uses deep-reach forklifts with telescopic forks that can extend to place or retrieve pallets in the second position. These specialized trucks are widely available in the UAE market and represent a relatively modest investment compared to the significant storage density gains they enable.

System Operation & Mechanics

Double deep racking uses the same structural components as selective pallet racking—uprights, beams, and bracing—but the frames are arranged in back-to-back pairs rather than single rows. This creates two pallet-deep storage positions on each side of the aisle.

Deep-reach forklifts feature telescopic fork carriages that can extend approximately 1,200mm beyond the standard reach position to access the rear pallet. The operator first places or retrieves the front pallet normally, then extends the forks to reach the second position. This operation adds only a few seconds to each put-away or retrieval cycle.

The system is typically configured with 3 or 4 beam levels, providing 6 to 8 pallets per bay face (compared to 3 to 4 in single-deep racking). Aisle widths are similar to reach truck operations at approximately 2,800mm to 3,200mm.

Double Deep Pallet Racking system details

Advantages

Key Benefits

Double Storage Density

Store twice as many pallets compared to single-deep selective racking by utilizing back-to-back frame configurations.

Fewer Aisles Required

Reduce the number of working aisles by up to 50%, freeing valuable floor space for other warehouse functions.

Cost-Effective Density

Achieve significant density gains at only 15-20% more cost than standard selective racking, making it one of the most economical high-density solutions.

Good Selectivity

While not 100% selective like single-deep racking, the system provides access to 50% of pallets at any time—sufficient for most medium-SKU operations.

Standard Components

Uses the same beam and upright profiles as selective racking, ensuring spare parts availability and easy maintenance.

Familiar Operation

Deep-reach trucks operate similarly to standard reach trucks, minimizing operator training requirements.

Industries & Use Cases

Medium-SKU distribution centers
Food and beverage warehouses
Consumer goods distribution
Manufacturing buffer storage
Retail distribution centers
Cold storage facilities
Paper and packaging warehouses
Chemical storage facilities

Technical Details

Pallet Depth2 pallets deep per side

Maximum HeightUp to 11,000mm

Beam Capacity1,000 to 4,000 kg per pair

Aisle Width2,800mm to 3,200mm

Fork ExtensionUp to 1,200mm telescopic

Frame ConfigurationBack-to-back paired

Pallet OverhangMaximum 50mm per side

StandardsEN 15512, FEM 10.2.02

Layout Planning for Double Deep Systems

Effective double deep layout planning requires careful analysis of your SKU count, pallet dimensions, and throughput patterns. Our design team creates detailed CAD layouts that optimize the ratio of double-deep to single-deep positions. In most warehouses, we recommend keeping 10-20% of positions as single-deep selective for fast-moving or irregularly-sized items, with the remaining 80-90% as double-deep for maximum density.

Integration with Warehouse Management

A warehouse management system (WMS) significantly enhances double deep racking efficiency. The WMS tracks which SKU is in each position (front and rear), directs operators to fill positions in the correct sequence, and optimizes retrieval paths to minimize empty travel. Most modern WMS platforms include double-deep storage rules as a standard feature. Our IT team can assist with WMS configuration and testing.

FAQ

Frequently Asked Questions

Yes, double deep racking requires a deep-reach forklift with telescopic forks. These trucks are available from all major forklift brands and cost approximately 15-25% more than standard reach trucks. The storage density gains typically far exceed the additional equipment cost.

When placing pallets, the rear position is filled first, then the front. When retrieving, the front pallet is taken first, then the rear. For optimal FIFO management, a warehouse management system (WMS) can track pallet positions and direct operators to the correct retrieval sequence.

In many cases, yes. If your existing frames and beams have sufficient capacity and your floor can support the additional loads, we can add back-to-back frames to convert single-deep bays to double-deep. Our engineers will assess the feasibility during a site survey.

Double deep works best when you have 50-500 SKUs with at least 4-6 pallets of each in inventory at any time. This allows you to dedicate two positions (front and rear) to the same SKU in each location, simplifying stock management.

Double deep racking typically increases storage capacity by 30-40% compared to selective racking in the same footprint. This is achieved by reducing the number of aisles by approximately half. While not as dense as drive-in racking, double deep offers better selectivity since you only lose access to one pallet per bay.

Double deep racking requires aisles of approximately 2.8-3.2 meters wide to accommodate deep-reach trucks. This is similar to standard reach truck aisles but wider than VNA aisles. The aisle width must allow the truck's telescopic forks to extend to full reach safely.

Yes, double deep racking is commonly used in cold storage and freezer facilities. The increased density helps reduce the total refrigerated volume required, lowering energy costs. All components are manufactured from cold-rated steel, and deep-reach trucks are available in cold storage specifications.

There is no theoretical maximum length. Items are supported across multiple arms, so lengths of 6 meters, 12 meters, or even longer can be accommodated by simply adding more columns to the run. We regularly design systems for 12m steel beams and 6m timber planks.

Double deep racking costs approximately 10-15% more per pallet position than selective racking due to the back-to-back frame configuration. However, you need fewer total bays for the same storage capacity, and the reduced warehouse space requirement typically delivers significant cost savings.

To access the rear pallet, the front pallet must be temporarily relocated. A WMS can identify the nearest empty position for the front pallet. While this adds time for individual picks, the overall warehouse efficiency gain from increased density usually outweighs the occasional need for double-handling.

Get Your Storage Solution Today

Contact Racking UAE for the best racking and shelving services in Dubai and across the UAE.

Contact Now

Double Deep Pallet Racking