We caught up with Mennolt from Queensland Storage Systems to talk about one of the most space-efficient variations of selective pallet racking Double Deep Pallet Racking.
For warehouses that need to increase storage capacity without adding new aisles or expanding the building, double deep racking can be a smart solution. As Mennolt explained, “It’s very similar to standard selective pallet racking, but instead of storing one pallet deep, you store two. That immediately doubles the storage in the same footprint.”
What Is Double Deep Pallet Racking
“Double deep racking is essentially two rows of selective pallet racking set back-to-back,” Mennolt said. “The pallets are stored two deep from the aisle, so you’ve got a front position and a rear position on every level. It lets you store twice as many pallets within the same run of racking.”
Each bay is designed so forklifts can reach the front pallet easily and the rear pallet using an extended-reach attachment. “It does require a specialised forklift or a double-deep reach truck to access the back pallet,” Mennolt explained. “That’s the main difference compared to standard selective systems.”
This design reduces the number of aisles required and significantly increases storage density. “You’re getting more pallets per square metre without sacrificing too much accessibility,” he said.
How Double Deep Racking Works
The system operates on a LIFO (Last In, First Out) basis. “Because the pallet at the front has to be removed before you can access the one behind it, it works best with bulk stock or common product lines,” Mennolt said. “It’s not suited for high-rotation stock where you need to pick individual pallets all the time.”
In a typical layout, forklifts store pallets two deep along the lane. “You can still see and reach most of your stock easily,” he explained. “It’s not as dense as drive-in racking, but it’s a really good middle ground between selectivity and storage capacity.”
Where Double Deep Racking Is Used
“You’ll often see double deep systems in distribution warehouses, cold storage facilities, and manufacturing environments,” Mennolt said. “Anywhere you’ve got repeat product lines or larger batch quantities. It’s also common in chemical or paint distribution where the products are similar, and space efficiency matters.”
He added that it’s particularly effective in warehouses that want higher density without going to full drive-in configurations. “It gives you a compact layout but still keeps the flexibility of selective racking. For many sites, it’s the right balance.”
Typical Design and Dimensions
A standard double deep bay will store two pallets deep, each level spanning roughly 1.35 to 2.7 metres wide. “Both the front and back bays are usually 838 millimetres deep, separated by a small gap of about 200 millimetres,” Mennolt said. “Occasionally you’ll see deeper setups, but that’s less common.”
He explained that heights are flexible depending on the warehouse and forklift type. “We usually design around what the equipment can handle, but four or five levels high is pretty normal,” he said. “Each level generally holds around one tonne per pallet, so about two tonnes per pair of positions.”
Benefits of Double Deep Pallet Racking
“Double deep is a great compromise between density and accessibility,” Mennolt said. “It gives you almost twice the capacity of selective racking without the cost or limitations of a full drive-in pallet racking system.”
It’s also cost-effective to install, especially for businesses upgrading an existing selective layout. “In a lot of cases, we can reuse frames and just change the beam spacing or add guide rails,” he said. “That makes it a relatively simple upgrade for a big increase in capacity.”
Ready To Maximise Space in Your Workplace?
If you’re looking to increase your warehouse storage capacity without sacrificing flexibility, Double Deep Pallet Racking might be the ideal solution. Call Mennolt and the team on 07 5537 5999 or submit an online enquiry. Our experts can help you design and install a racking configuration that maximises space, improves workflow, and supports your operation long-term.
About Mennolt Regtien
Mennolt Regtien brings more than 20 years of hands-on experience in the storage and pallet racking industry in Australia, backed by a broader career spent helping businesses grow, improve productivity and solve operational challenges. Before moving into pallet racking and storage systems, he spent around 10 years consulting to small and medium businesses on growth and development, and earlier worked in venture capital and startups, including helping Australasian companies expand into Asian and US markets.
His experience helps him look beyond the racking itself to understand each client’s wider business goals, identify operational issues quickly, and recommend storage solutions that support both efficiency and future growth.
