Store more pallets in the space you already have. Double deep pallet racking gives you a high-density storage system without losing the flexibility of a standard racking layout. Designed, supplied and installed by 2h Storage Solutions for warehouses across Yorkshire and the North East.
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What is double deep pallet racking?
Double deep pallet racking stores pallets two deep on each side of the aisle. Instead of one pallet per bay position, each position holds two, one behind the other. Because two rows of racking sit back to back as a single block, you need fewer aisles to serve the same number of pallets.
The result is more pallet positions in the same floor area, and less floor space given over to aisles. It is one of the most cost-effective ways to increase capacity without moving premises or building upwards.
Double deep racking uses the same basic components as conventional selective racking: upright frames and load beams. The difference is in the layout and the handling equipment used to reach the second pallet.
How does double deep racking work?
Pallets are loaded and unloaded from the aisle side only. The first pallet is placed on the front beams. The second is placed behind it, using a truck with extending or telescopic forks that can reach into the rack.
This means:
- Fewer aisles. One aisle serves two pallet positions deep on both sides.
- Higher density. More pallets fit in the same footprint, typically in the region of 30–40% more pallet positions than single deep selective racking, depending on your building and layout. [Confirm figure against your own project data.]
- A different stock rotation. The rear pallet cannot be reached until the front pallet is removed, so the system is best suited to a last in, first out approach.
Is double deep racking right for your warehouse?
Double deep racking works best when you hold several pallets of the same product and can store them in pairs. It is a strong fit if:
- You are running out of pallet positions and cannot expand the building
- You store a relatively small number of product lines in larger quantities
- Your stock rotation is flexible, or you work on a last in, first out basis
- You want to improve capacity without the extra cost and complexity of automation
- You are considering a move to larger premises and want to know whether better use of space could avoid it
It is less suitable if you need immediate access to every individual pallet, or if you hold large numbers of different products with only one or two pallets of each. In those cases, standard adjustable pallet racking, push back racking or pallet live storage may be a better fit. We will always tell you if a different system suits your operation better.
Benefits of double deep pallet racking
More capacity from the same footprint. Removing every other aisle frees up floor space for extra racking.
Lower cost per pallet position. Compared with automated or heavily mechanised systems, double deep racking is a relatively low-cost way to increase density.
Familiar, flexible structure. It uses standard racking components, so it can be extended or reconfigured as your needs change. [Confirm this applies to the systems you supply.]
A good halfway step. It sits between conventional selective racking and deeper high-density systems such as drive in racking, giving you more capacity while keeping better access to your stock.
Works with your existing layout. In many cases we can convert part of a warehouse to double deep racking without a full re-fit.
Things to consider before you invest
We believe in giving you the full picture. Before specifying double deep racking, we look at:
- Handling equipment. You will need reach trucks with extending forks, or similar, capable of placing pallets in the rear position at your required heights. Your existing fleet may or may not be suitable.
- Stock rotation and product mix. If first in, first out is essential, or you hold many single-pallet product lines, the density gains may not be worth the reduced access.
- Pallet quality and size. Consistent, good-condition pallets matter more in deeper systems.
- Floor and building constraints. Floor flatness, column positions, sprinkler layout and rack height all affect what is possible.
- Fire protection. Higher-density storage can change your sprinkler requirements, so we consider this at design stage. We can also supply and install in-rack sprinkler systems.
Our double deep racking service
From first conversation to handover, we manage the whole project:
- Free survey and discussion. We visit your site, measure your space and talk through how you operate: your products, throughput, trucks and growth plans.
- Layout design. We produce racking layouts showing how many pallet positions you could gain compared with your current set-up, and how different systems compare.
- Specification and quotation. We specify the right components for your loads and give you a clear, itemised quote.
- Installation. Our installation teams fit your racking safely and to a programme that suits your operation, including phased installs where you need to keep working. [Confirm.]
- Handover and load notices. We provide the safe working load information you need, so your team knows the capacity of each bay. You can also check typical capacities using our rack capacity tool.
- Ongoing inspections. We offer pallet racking safety inspections to help you meet your obligations under the Provision and Use of Work Equipment Regulations (PUWER) 1998 and the Health and Safety at Work Act 1974.
Safety and compliance
Racking is structural equipment that carries heavy loads, so safety is built into everything we do. Our designs take account of the loads you plan to store, the rack configuration and your handling equipment. Once installed, racking should be inspected regularly: this includes your own routine visual checks and a periodic inspection by a competent person. [Add accreditations, such as SEMA membership or SARI-qualified inspectors, if applicable.]
Double deep racking compared with other high-density systems
| System | Best for | Access to pallets | Density |
|---|---|---|---|
| Adjustable pallet racking | Many product lines, full access to every pallet | Every pallet | Standard |
| Double deep racking | A moderate number of lines, with 2 or more pallets per line | Front pallet first | Higher |
| Drive in racking | Large quantities of few product lines | Last in, first out, lane by lane | Very high |
| Push back racking | Medium to high density with several pallets per lane | Last in, first out, lane by lane | High |
| Pallet live storage | High-throughput, first in, first out | First in, first out | High |
Not sure which suits you best? Our team will compare the options against your actual stock profile and give you an honest recommendation.
Frequently asked questions
How much extra capacity can I get with double deep racking? The gain depends on your building, ceiling height and current layout, but double deep racking commonly provides a significant increase in pallet positions compared with single deep selective racking, because it needs fewer aisles. We can show you the difference on a layout drawing during your survey.
What trucks do I need for double deep racking? You need trucks that can reach the second pallet position, typically reach trucks with extending (telescopic) forks. Your existing fleet may not be suitable, so we recommend checking this early. We can advise on what is needed for your rack height and loads.
Can I use double deep racking for first in, first out stock rotation? Not easily. Because the rear pallet is blocked by the front one, double deep racking generally suits last in, first out, or situations where pallets of the same product are interchangeable. If strict first in, first out is essential, pallet live storage may be a better option.
Can my existing racking be converted to double deep? Sometimes. It depends on the existing frames and beams, your aisle widths and your handling equipment. A survey will tell you whether conversion or new racking makes more sense.
How long does installation take? That depends on the size of the project, from a few days for a small installation to several weeks for a full warehouse. We plan the programme with you to minimise disruption to your operation.
Do you install double deep racking outside Yorkshire? Our main coverage is Yorkshire and the North East. See our areas covered, or contact us to discuss your location.
Does double deep racking need inspecting? Yes. Like all pallet racking, it should be inspected regularly to check for damage and keep your safe working loads valid. See our racking inspection service.
Double deep racking across Yorkshire and the North East
We supply and install double deep pallet racking from our base in Wetherby, serving businesses in Leeds, York, Harrogate, Sheffield, Doncaster, Hull, Newcastle, Sunderland, Middlesbrough, Darlington and across the region. [Link each town to its location page.]
Ready to get more from your warehouse?
Tell us about your space and your stock, and we will show you what double deep racking could do for your capacity, with no obligation.
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2h Storage Solutions Ltd, Unit 7 Sandown House, Sandbeck Way, Wetherby, West Yorkshire LS22 7DN 01937 858151 | enquiries@2hssl.com