Double Deep Racking Dimensions and Size Guide

Time:7/7/2025

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Double deep racking is a popular warehouse storage solution designed to increase storage density while maintaining accessibility and efficiency. As the name suggests, this racking system stores pallets two-deep instead of one-deep, effectively doubling storage capacity compared to selective pallet racking systems in the same footprint.

Understanding the dimensions and layout options of double deep racking is essential for warehouse planners, logistics managers, and facility designers. In this guide, we’ll walk through the standard dimensions, key design considerations, and tips to optimize your warehouse layout using double deep racking systems.

What Is Double Deep Racking?

Double deep racking is a type of high-density pallet racking that allows two pallets to be stored back-to-back in each lane. It’s essentially two selective racking rows placed one behind the other, requiring a deep reach forklift or specialized equipment to access the second pallet.

This system offers a good balance between increased storage capacity and relatively simple operation, making it ideal for operations with a medium turnover rate and multiple pallets of the same SKU (stock keeping unit).

Standard Double Deep Racking Dimensions

While dimensions can be customized depending on pallet size, warehouse height, and aisle width, the following are typical standard measurements used in most warehouses:

Pallet Size: 1200mm (L) × 1000mm (W) is a common standard in many regions

Rack Depth: Approximately 2700mm to accommodate two pallets (including clearance)

Bay Width: Around 2700mm to 2800mm for two pallets side by side

Upright Height: Ranges from 2000mm up to 12000mm or more, depending on vertical storage needs

Beam Levels: Usually 2 to 6 levels, adjustable based on load height and lifting equipment

Aisle Width: Requires a minimum of 3000mm to 3500mm for deep reach truck operation

These dimensions may vary depending on pallet configuration (e.g., 1200×800mm Euro pallets), rack manufacturer, or regional warehouse standards.

Key Design Considerations

When planning a double deep racking layout, several critical factors should be considered:

1. Forklift Type

Double deep systems require specialized forklifts with extendable forks (deep reach trucks). These vehicles must be able to reach the second pallet without compromising stability or safety.

2. Product Turnover Rate

Because the back pallet cannot be accessed without moving the front one, double deep racking is best suited for LIFO (Last-In, First-Out) inventory management or products with medium-to-low turnover rates.

3. Load Weight and Dimensions

Ensure that each pallet does not exceed the beam’s load capacity. Beams and uprights must be selected according to your heaviest SKU dimensions and weight, with safety factors included.

4. Floor Space Optimization

Double deep systems reduce aisle count, maximizing pallet positions per square meter. However, adequate turning radius for lift trucks must be maintained to ensure safe operation.

5. Rack Safety Features

Incorporate accessories like pallet backstops, frame protectors, and beam locking pins to enhance safety and reduce the risk of pallet push-through accidents.

Advantages of Double Deep Racking

Increased Storage Density: Up to 30–40% more storage capacity than selective racking.

Cost-Effective: Lower cost per pallet position compared to drive-in or AS/RS systems.

Flexibility: Easily reconfigured or adjusted as inventory needs change.

Efficient Use of Vertical Space: Suitable for high-bay warehouses.

Limitations to Consider

Reduced Selectivity: Not all pallets are immediately accessible.

Special Equipment Required: Deep reach trucks are necessary.

Training and Safety: Operators need proper training due to the added complexity of pallet handling.

Conclusion

Double deep racking systems are an efficient and practical solution for increasing warehouse capacity without major structural changes. By understanding the standard dimensions and considering equipment and inventory flow, businesses can implement a system that balances density, accessibility, and cost.

Before installing a double deep racking system, it’s important to work with a qualified racking supplier or warehouse design consultant who can tailor the layout to your specific operational needs. Whether you're upgrading an existing facility or designing a new one, double deep racking offers a flexible and scalable path to better storage efficiency.

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