Most warehouses default to standard selective racking, one pallet position per bay, because it’s simple and every pallet is directly accessible. Double deep racking asks a fair question: what if you stored two pallets deep in every bay instead of one, and accepted a small trade-off in access for a real gain in capacity?
What double deep racking actually is
Double deep racking looks like standard pallet racking, but each bay is built to hold two pallets back-to-back rather than one. A reach truck fitted with extending forks (or a double-deep-specific truck) reaches past the front pallet to place or retrieve the one behind it, without needing a second aisle.
The capacity gain
Because two pallets share the depth of what would otherwise be one bay’s worth of aisle space, double deep racking can meaningfully reduce the number of aisles needed for the same number of pallet positions. For warehouses running out of floor space but not ready to commit to fully narrow-aisle or shuttle systems, it’s often the first upgrade considered.
What you give up: full selectivity
The rear pallet in each pair is only accessible once the front one has been removed, so double deep racking works best when both pallets in a pair hold the same product, or where access order genuinely doesn’t matter. It’s a poor fit for warehouses handling a large number of different SKUs in small quantities, since half the positions become awkward to reach on demand.
The equipment question
Double deep racking typically needs reach trucks with extending forks rather than standard counterbalance trucks, which usually means either investing in the right equipment or confirming your existing fleet can handle it. This is worth costing out properly before committing to the layout, since it changes the economics of the decision.
Where it fits best
Warehouses with a smaller number of high-volume SKUs, seasonal stock that arrives and leaves in bulk, or overflow storage for slower-moving lines tend to get the most out of double deep racking. It’s a genuine middle step between standard racking and the higher-density, higher-cost systems like narrow aisle or pallet shuttle.
And finally…
Double deep racking isn’t a universal upgrade, but for the right stock profile it’s a straightforward way to meaningfully increase capacity without a wholesale redesign of your warehouse.
If you’re trying to work out whether double deep racking suits your stock and your equipment, Rackline can help you think it through. Call 01782 770144, email info@rackline.co.uk, or get in touch via the form below.
*Double deep racking is just one of several ways to get more from a warehouse layout, see how push back racking, pallet shuttle systems, adjustable warehouse racking, and VNA racking compare if you’re weighing up the full range of options.