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Double Deep Pallet Racking

Double deep pallet racking doubles the capacity of every location by storing pallets two rows deep, front to back, instead of a single pallet per lane. It is one of the simplest ways to add storage without moving to a bigger building. If floor space is tight and stock turnover is steady rather than frantic, this is often the most cost-effective system on the table.

Dalvie Systems designs, supplies and installs double deep pallet racking for warehouses across Wolverhampton, Birmingham, the West Midlands and the wider UK. We have delivered racking and storage projects for names including JLR, DHL and BOSCH, and we install to recognised safety standards through our accredited team.

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A high-density deep racking system

Double deep racking uses the same adjustable steel frames and beams as standard or wide aisle racking. The difference is depth. By placing two runs of racking back to back, each aisle serves twice the pallets, so you need fewer aisles and hand more of the floor over to storage.

That extra density suits distribution, manufacturing, and food and drink operations where the same product moves in volume. Because pallets at the back are reached over the ones in front, double deep is a last in, first out (LIFO) system, best for stock with a medium to long shelf life. It is not the right choice for highly perishable goods that need strict date rotation.

The handling equipment you need

The one practical requirement is the truck. Double deep pallet racking is worked with a reach truck or an articulated forklift fitted with a double deep handling attachment, so the operator can place and retrieve the second pallet. A hydraulic or telescopic attachment slides the forks in and out to reach the rear position.

This kind of equipment keeps aisles narrow and protects your stock. Compared with manual fork extensions, a telescopic or pantograph attachment gives the driver clear visibility and smooth, controlled loading, which cuts the risk of knocked pallets and damaged racking. Pantograph or scissor-mast trucks are also well suited to double deep work, pairing fast cycle times with tight aisle widths.

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Why Use Double Deep Pallet Racking?

Double deep pallet racking doesn’t permit access to all the stored pallets. However, this is more than compensated for by the fact it creates an efficient system of stock control, offering a distinct advantage in terms of extra storage space. Double deep pallet racking is best suited to a last in, first out storage system and is ideal for stock with a medium to long-term shelf life. It is not recommended for highly-perishable goods.

Using pallet handling equipment such as a forklift with a double deep handling attachment or a specialised forklift, this provides access to the pallets. The forklift most commonly used is a reach truck or an articulated forklift, which can operate in double deep, narrow aisles. A forklift with a hydraulic or telescopic attachment is ideal for double deep pallet racking – hydraulic pumps will move the forks in and out, allowing the operator to place stock in the second row.

This type of pallet handling equipment reduces the required aisle width and is a cost-effective handling solution that can also reduce possible stock damage when compared with manual fork extensions, offering clear visibility for the handler.

Other suitable handling equipment for includes pantographs/scissor mast trucks – for stacking double deep pallets and providing fast operating times. They can be used in reduced aisle widths, minimising possible pallet damage thanks to their smooth operation – used with counter-balance trucks for loading and unloading the freight trucks.

In terms of cost-effectiveness, the initial expenditure on double deep pallet racking is countered by the benefits of increased storage capacity and efficient operations.

How double deep compares to other pallet racking systems

Choosing between racking systems comes down to how your stock moves. Double deep sits between the density of drive-in and the accessibility of wide aisle, so it helps to see it alongside the alternatives.

Adjustable and selective pallet racking

Standard wide aisle pallet racking, also known as adjustable pallet racking (APR) or selective racking, gives direct access to every pallet. It is the most flexible option for mixed stock, but it uses the most floor space. Double deep trades a little of that selectivity for a large gain in density.

Narrow aisle pallet racking

Narrow aisle pallet racking squeezes the aisles down and lifts capacity while keeping every pallet reachable, using specialist trucks. Double deep reaches a similar density from a different direction, by adding depth rather than closing the aisles.

Drive-in and push back racking

For the highest density on a small number of SKUs, drive-in pallet racking and push back pallet racking store pallets several deep. They give up more selectivity in return. Double deep is the middle ground when you want more capacity but still need reasonable access to individual lines.

We also supply mobile pallet racking, multi-tier racking and pallet live racking, so the recommendation is always matched to your building and your stock rather than a single default.

Deep pallet racking systems built around your stock

There is no standard double deep layout. Beam and frame loadings, bay sizes, pallet dimensions and the trucks you already run all shape the design. Our team assesses your warehouse, works out the safe configuration, and builds the racking around how goods actually move through the site.

Racking installation is handled by our own accredited installers, so the system goes in safely and to spec, with minimal disruption to your day. We can phase the work around live operations and return to add more racking as you grow. Ongoing rack inspection and repair keep it safe and compliant for the long term.

Talk to our double deep pallet racking team

If you are weighing up double deep against other racking systems, the quickest way forward is a short conversation and a site assessment. We will tell you honestly whether double deep is the right fit, and quote a bespoke system for your space.

Get in touch with our team or call 01902 783784 to talk it through. 

Frequently Asked Questions

What is double deep pallet racking?

Double deep pallet racking stores pallets two deep, one behind the other, instead of a single pallet per lane. It uses the same adjustable frames and beams as standard racking, with a reach or articulated truck accessing the rear pallet. The result is far more storage in the same floor space.

The cost depends on the size of your warehouse, the number of bays, the beam and frame loadings, and whether you need handling equipment that can reach the second pallet. Every layout is quoted individually, so the best guide to your investment is a site assessment and a bespoke quote from our team.
Double deep racking is worked with reach or articulated trucks, so aisles sit between wide aisle and narrow aisle widths. The exact figure depends on the truck you run and your pallet size, which is why we confirm it at the design stage rather than quoting a single number for every warehouse.
Double deep is not the same as double stacking. Double deep stores pallets two rows deep, front to back, on the same beam level. Stacking one pallet directly on top of another depends on load stability and weight, and is usually handled by adding beam levels rather than balancing pallets on top of each other.

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