Every warehouse eventually runs into the same wall: more inventory than aisles can reasonably support. Double deep racking answers that problem directly by storing pallets two positions deep instead of one, without giving up as much access as some denser systems demand.
At Accurate Shelving, this guide breaks down exactly how much density double deep racking actually delivers, what equipment it requires, and where it fits best.
What Is Double Deep Racking?
Before getting into the numbers, it helps to understand exactly what changes structurally from a standard system.
Two pallet positions instead of one, in the same bay
Double deep racking stores pallets back to back, two positions deep on each side of an aisle, using the same basic frame and beam components as standard selective racking.
A deeper frame, not an entirely different system
The structure looks and functions like familiar pallet racking, just engineered with a deeper configuration to hold the second pallet position behind the first, rather than requiring an entirely unfamiliar setup.
How Much Storage Density Can You Actually Gain?
This is the question most buyers actually care about, and the answer comes down to a straightforward trade.
Roughly double the pallet positions in the same footprint
Storing two pallets deep instead of one effectively doubles storage capacity within the same floor space, largely by reducing the number of aisles a facility needs to maintain between rows.
Fewer aisles also means less total travel distance for equipment moving through the facility, an advantage that compounds in larger warehouses running many rows of racking end to end. Some operations push further into a three-deep configuration for even greater density, though that setup demands tighter load planning and stricter LIFO discipline to keep retrieval predictable.
That density comes with a real access trade-off
Direct access drops to roughly half of what a fully open system offers, since the rear pallet can only be reached once the front pallet in that same lane has been removed first. That trade-off is worth weighing carefully against how often a facility actually needs to reach every pallet position individually, rather than moving product in and out by the lane.
What Equipment Does Double Deep Racking Require?
Density gains like this don’t come free. They depend on equipment built specifically for the job.
Standard forklifts can’t reach the back position
Regular counterbalanced forklifts and standard reach trucks stop short of the rear pallet, making specialized equipment a requirement rather than an optional upgrade for any facility considering this system.
Deep-reach trucks extend forks to reach the rear pallet
A pantograph mechanism extends the fork carriage forward, often by more than a meter beyond the standard position, letting the truck place and retrieve the back pallet without driving fully into the rack structure.
That extended reach connects directly to choosing the right material handling equipment for a racking layout in the first place, since aisle width, mast height, and fork travel all have to be planned around the specific truck being used. Because that equipment needs room to extend and maneuver precisely, double deep aisles are typically planned somewhat narrower than a standard selective layout, but still noticeably wider than the very narrow aisle configurations built for turret trucks.
Operators also need dedicated training on double deep retrieval specifically, since placing a pallet accurately in the rear position takes more precision than a standard single-depth pick.
Which Products and Inventory Types Fit Double Deep Racking Best?
Not every inventory profile benefits equally from this system, and matching the right product to it matters.
LIFO rotation suits non-date-sensitive inventory
Because the rear pallet is the last one placed and the first one retrieved, double deep racking works best for products that don’t depend on strict first-in-first-out rotation to avoid spoilage or waste.
Fewer SKUs per lane keeps the system efficient
Operations typically get the best results storing two to four SKUs per lane, since too much variety behind a single front pallet makes retrieval slower and less predictable for staff working the floor.
Products with steady, high-volume movement tend to suit this system better than slow-moving or highly seasonal inventory, since the lane needs to turn over regularly enough that the rear pallet doesn’t sit untouched for long stretches.
How Does Double Deep Compare to Selective and Drive-In Racking?
Understanding where this system sits relative to its neighbors makes the decision easier to reason through.
More density than selective, more access than drive-in
Double deep occupies the middle of the spectrum: it roughly doubles the capacity of fully open selective racking, while still keeping meaningfully more direct access than deep drive-in systems, which can run six to twelve pallets deep with almost no individual access at all.
For a facility that needs more density than selective offers but can’t accept the access limitations of drive-in, double deep is often the practical middle ground.
Existing selective racking can often convert to double deep
Because the two systems share the same core components, a facility already running selective racking may be able to reconfigure into a double deep layout rather than starting over with an entirely new system from scratch. That conversion path is worth exploring first for any operation looking to increase density without replacing racking that’s already structurally sound.
What Safety Considerations Apply to Double Deep Racking?
Getting the density and equipment right still leaves one more factor that shouldn’t be an afterthought.
Forklift entry increases the risk of column impact
Because deep-reach trucks and their outriggers operate closer to the rack structure than standard forklifts do, columns face a higher risk of impact damage than in less demanding storage systems.
Column protection and cold storage construction both matter
Guards at vulnerable column positions reduce impact risk, and facilities using double deep racking in freezer or cold storage environments typically need galvanized frames built to handle the added humidity and temperature swings that come with that setting.
The same density gain that helps a standard warehouse also helps a cold storage facility keep a smaller footprint under refrigeration, which matters directly for energy cost given how much more expensive cooled space is to maintain than ordinary floor space.
Getting Double Deep Racking Right
Double deep racking delivers a real, meaningful density gain without the near-total loss of access that comes with deeper storage systems, provided the right equipment and safety measures are in place from the start.
Accurate Shelving has spent over 21 years designing and installing pallet racking systems across Canada, including double deep configurations engineered around your actual inventory and equipment. Reach out through Contact Us for a hands-on assessment of whether double deep racking fits your warehouse.
Frequently Asked Questions
How much more storage does double deep racking provide compared to selective?
It roughly doubles pallet positions within the same footprint by storing pallets two deep instead of one, though direct access drops to about half.
Can a standard forklift access double deep racking?
No, a deep-reach truck with an extending pantograph fork mechanism is required to reach the rear pallet position safely.
Is double deep racking suitable for date-sensitive inventory?
Not usually, since it operates on a last-in-first-out basis, it fits non-date-sensitive products better than perishable or strictly rotated goods.
Can existing selective racking be converted to double deep?
In many cases yes, since both systems share the same core frame and beam components, making conversion more practical than starting with an entirely new system.
Does double deep racking need extra safety measures?
Yes, column guards are commonly used to protect against forklift impact, since deep-reach trucks operate closer to the rack structure than standard equipment does.
