What is double-deep pallet racking, and what equipment do I need to use it?
Quick Answer
Double-deep pallet racking places two rows of selective racking back to back so that pallets are stored two positions deep from the aisle. This increases storage density by roughly 30 to 40 percent over standard selective racking while still using a familiar beam-and-upright structure. The trade-off is that you need a deep-reach forklift (also called a double-deep reach truck) to access the back pallet position. Warehouse Cubed designs double-deep layouts matched to your lift equipment and inventory profile.
Detailed Answer
Double-deep racking is one of the simplest ways to gain meaningful storage density without moving to a fully specialized system like drive-in or push-back. Instead of a single row of selective racking accessed from the aisle, two rows are placed back to back. The front pallet is accessible directly, and the back pallet sits one position deeper behind it. Because you are storing two pallets deep on each side of the aisle, you eliminate roughly every other aisle compared to a standard selective layout. That recovered floor space translates into additional rack rows and more total pallet positions in the same building footprint.
The equipment requirement is the most important consideration. A standard counterbalanced forklift cannot reach the back position. You need a double-deep reach truck equipped with an extended scissor-style carriage (sometimes called a pantograph) that telescopes the forks forward to place or retrieve the second pallet. These trucks cost more than a standard reach truck, so if your facility already operates reach trucks, confirm with the manufacturer whether your model supports a deep-reach attachment before investing in new equipment.
Double-deep racking introduces a selectivity trade-off. The back pallet is only reachable once the front position is empty. If you slot two pallets of the same SKU in each position, this is a non-issue. If space pressure forces you to store different SKUs in the same position, you may find yourself shuffling pallets. This makes the system best suited for operations that carry moderate SKU counts with at least two to four pallets of each product on hand. Distribution centers handling consumer goods, beverage, and building materials are common applications.
Aisle width requirements are comparable to standard reach truck aisles at roughly 9.5 to 11 feet. The density gain comes entirely from eliminating aisle count, not from tightening aisle width. Clear height is also worth verifying. A fully extended pantograph carriage can experience deflection at maximum lift heights, which may slightly reduce your usable storage height compared to single-deep selective racking.
Warehouse Cubed’s layout and design team models double-deep configurations alongside selective and other density options so you can compare total pallet positions, equipment costs, and operational impact side by side. If you are running out of space but want to stay within a familiar rack structure, a free consultation will tell you whether double-deep is the right next step for your facility.