Double Deep Pallet Racking System
Maximize warehouse storage density by up to 40% over selective racking — without sacrificing forklift accessibility. Gieantech's double deep pallet racking stores two pallets deep per bay, eliminating unnecessary aisles while maintaining efficient FILO inventory flow.
What Is Double Deep Pallet Racking?
Double Deep Pallet Racking is a high-density storage solution that places one row of pallet racking behind another. By storing two pallets deep, it significantly reduces the number of access aisles required, increasing floor space utilization by approximately 40% compared to standard selective systems.
This system operates on the First-In Last-Out (FILO) principle for each pair of pallets. It requires specialized deep-reach forklifts equipped with telescopic forks or a pantograph mechanism to access the rear pallets. Built from high-grade Q235B steel, our racking supports loads up to 4,000kg per level and has been trusted by clients in over 57 countries.
40% More Pallet Positions
Increase density by storing two pallets deep in each bay.
4,000 kg Load per Level
Heavy-duty engineering for industrial weight requirements.
10,000+ mm Maximum Height
Vertical scalability to maximize your warehouse cube.
FILO Inventory Method
Optimized for multi-pallet storage of the same SKU.
2 Pallets Deep Per Bay
Double-deep configuration eliminates every second aisle.
50% Fewer Aisles Required
Reclaim floor space for more storage capacity.
Why Choose Double Deep Racking?
40% More Storage
Eliminate unnecessary aisles to pack more inventory into the same footprint.
Heavy Load Capacity
Q235B high-tensile steel supports up to 4000kg per beam level.
Deep-Reach Compatible
Engineered for standard telescopic and pantograph reach trucks.
Lower Cost per Pallet
Reduced infrastructure cost compared to high-density automated systems.
Same Components
Uses 90% same components as selective racking for easy maintenance.
Convertible System
Can be easily reconfigured back to selective racking if warehouse needs change.
Cold Storage Ready
Fully operational in temperatures as low as -30°C for freezer applications.
Adjustable Heights
Beams are adjustable on a 50mm or 75mm pitch to fit various pallet sizes.
Double Deep Racking Configurations
Standard Double Deep
The core FILO configuration using back-to-back rows to increase storage density by 40% using a single aisle.
Double Deep with Pushback
Gravity-assisted rails added to double deep lanes for smoother pallet retrieval and improved speed.
Double Deep Narrow Aisle
Combining double-deep bays with VNA (Very Narrow Aisle) widths using specialized turret trucks.
Cold Storage Double Deep
Optimized for -30°C environments where high density is critical for energy efficiency and space cost.
System Component Breakdown
Upright Frames
High-grade Q235B steel. Column depths up to 1200mm to support two-pallet deep loads with maximum stability.
Box Beams
Heavy-gauge box or step beams engineered for spans up to 3600mm and loads up to 4000kg per pair.
Bracing Systems
Diagonal and horizontal bracing designed to withstand dynamic forces during deep-reach pallet handling.
Column Protectors
Heavy-duty steel floor protectors to shield uprights from potential forklift impact in high-traffic aisles.
Wire Mesh Decking
Optional safety decks for non-standard pallets, providing fire protection and debris prevention.
Row Spacers
Critical ties that connect back-to-back rows, ensuring rigid alignment and structural integrity.
Engineering Data & Parameters
📏 Structural
- Bay Width1.8 - 3.6m
- Frame Depth800 - 1.2m
- HeightUp to 10.5m
- Levels2 - 6 Levels
- Aisle2.8 - 3.5m
🏗️ Material
- Steel GradeQ235B
- Upright Gauge1.5 - 2.5mm
- FinishPowder Coat
- Coating60 - 80μm
- ColorsCustom/Std
🛡️ Load & Safety
- Capacity/LvlUp to 4000kg
- Capacity/BayUp to 16t
- Safety Factor1.5 - 2.0
- LockingTeardrop/Bolt
- SeismicZone IV Rated
🚢 Logistics
- MOQ50 Bays
- Lead Time20 - 35 Days
- TermsFOB/CIF/EXW
- Warranty10 Years
- PortsShanghai/Ningbo
Double Deep Solutions Across Industries
3PL & Distribution
Cold Storage
Food & Beverage
Manufacturing
Retail & E-Commerce
Pharmaceutical
Automotive
Building Materials
Double Deep vs Other Pallet Systems
| Feature | Double Deep | Selective | Drive-In | Narrow Aisle |
|---|---|---|---|---|
| Space Utilization | 60-65% | 40% | 75-80% | 50-60% |
| Selectivity | 50% | 100% | 20% | 100% |
| Storage vs Selective | +40% | Baseline | +75% | +25% |
| Inventory Method | FILO | FIFO | LIFO | FIFO |
| Forklift Type | Deep-Reach | Standard | Specialist | Turret Truck |
| Aisle Width | 2.8-3.5m | 3.5-4.5m | N/A | 1.6-1.9m |
| Cold Storage Best | Yes | Moderate | Excellent | Good |
| Cost vs Selective | +10-15% | Baseline | +30% | +40% |
| Best For | Med-High Density | High Selectivity | Bulk Storage | High Density |
Design & Engineering Process
Consultation
We analyze your pallet data, throughput requirements, and forklift capabilities.
CAD Layout
Our engineers create 3D CAD designs to maximize your floor space efficiency.
Engineering
Load calculations and seismic analysis ensuring structural safety and durability.
Manufacturing
Precision fabrication using high-grade steel with automated powder coating.
Logistics
Safe container loading and global shipping to your facility's nearest port.
Installation
Detailed assembly guides and on-site or remote commission support.
Factory Direct
Cut out the middleman with direct-from-manufacturer pricing.
Free CAD Design
Complimentary professional warehouse layout optimization.
Convertible System
Future-proof design that grows and adapts to your needs.
57+ Countries
Global experience in various regulatory environments.
ISO 9001 QC
Rigorous quality control at every stage of production.
10-Year Warranty
Industry-leading guarantee on all structural components.
Why Gieantech?
Gieantech is a premier global manufacturer of warehouse racking systems. We combine advanced engineering with high-quality materials to deliver storage solutions that last decades.
Frequently Asked Questions
Ready to Increase Storage by 40%?
Contact Gieantech today for a free warehouse layout design and factory-direct quote. Our engineering team is ready to optimize your space.