Double deep pallet racking stores two pallets back-to-back in each bay, rather than one. It increases storage density by reducing the number of access aisles needed while keeping the system accessible by forklift – unlike drive-in racking, which stores pallets much further back.
It requires a reach truck with a pantograph attachment to access the rear pallet position. That equipment consideration aside, it offers a practical middle ground between selective racking and full high-density systems. Absolute Storage Systems designs and installs double deep racking across Victoria, configured to your reach truck specifications and floor layout.
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Double deep racking uses standard upright frames and beams, configured so that each bay holds two pallet positions front-to-back rather than one. A reach truck with an extended pantograph mechanism accesses both positions from the aisle, without the forklift needing to enter the rack.
The result is roughly double the storage density of selective racking in the same floor area, with fewer aisles required. The trade-off is that rear pallets can only be accessed once the front pallet has been moved, so it’s best suited to stock where a small reduction in picking flexibility is acceptable.
Double deep racking is only as effective as the reach truck clearances and bay configurations it’s designed around. Mismatched equipment or incorrect bay depth causes operational bottlenecks fast. Absolute Storage Systems has been specifying racking systems for Victorian warehouses since 1991.
We assess your reach truck specifications, pallet dimensions and floor layout to confirm double deep racking is the right fit.
We design bay depth, beam levels and load ratings around your reach truck and pallet specifications.
Professionally installed in line with AS4084:2023, ready to load from day one.
We check beam locking, frame stability and load signage before handover.
We provide racking audits, maintenance and reconfiguration as your storage needs change.
When selective racking isn’t dense enough but a full drive-in system doesn’t suit your product mix, double deep racking provides a practical middle ground. It roughly doubles storage density compared to selective racking while keeping pallets accessible from the aisle.
If you’re running out of floor space and selective racking isn’t dense enough, double deep is worth exploring before committing to a full high-density system. Our team can assess your warehouse and reach truck setup, contact us to get started.
Double deep racking typically adds in the order of 20% to 40% more pallet positions in the same floor area compared with selective racking, by halving the number of aisles. Floor space utilisation commonly improves from around 40% to 45% with selective racking to above 60% with a well-planned double deep layout. The actual gain depends on your building shape and how well products are slotted.
Only the front pallet in each pair has direct access, so half the positions behave last in, first out and you lose some selectivity. Partly emptied bays leave a position that cannot be used for another product line, which is known as honeycombing. And it needs a reach truck with a deep reach or pantograph attachment, which is a genuine cost step up from a standard counterbalance forklift.
Double deep works best where you routinely hold at least four pallets of the same product, so both positions in a pair can be filled with the same line. Below that, bays end up half full with stock you cannot mix, and the density gain disappears. It is a stock profile decision as much as a racking one, which is why we look at your product lines and pallet volumes before recommending it.
Double deep stores two pallets deep and is loaded from an aisle with a deep reach truck, so the forklift stays outside the racking. Drive-in stores several pallets deep in a lane the forklift drives into. Drive-in gives more density; double deep keeps more selectivity and takes less impact damage. Double deep is usually the step up from selective racking, and drive-in the step beyond that
Yes, and it is a common choice there. Cold storage space is expensive to run, so the reduction in aisle space has a direct effect on refrigeration cost. It works well where a cold store holds a limited number of product lines in reasonable volume, and where last in, first out rotation on the rear position is workable.
As per the Australian Standard (AS4084:2023), pallet racking audits are now mandatory and must be completed every 12 months.
Ensure your facility is safe and fully compliant with a free onsite audit from our expert team.
