Double Deep Pallet Rack

Double deep racking is created by placing 2 double-sided runs together. Pallets are stored 2 deep and are accessed using special trucks with pantograph or telescopic forks. Using a deep reach lift truck, the operator places the back pallet into the system first, then places another pallet in front of it. While selectivity has been reduced by one-half over standard pallet rack, twice as many pallets are stored for a given number of aisles. This increases productive use of floor space about 60% to 65%. The system requires the use of a special reach truck with either dual pantograph or slide fork attachments. Truck lift heights are limited by load to about 9 metres. Upper levels can be fitted with guide rails to assist forklift drivers in locating pallets, they also help reduce fork truck operator error and accidental impact damage.

The advantage of two-deep rack facings (perpendicular to the aisle) is that fewer aisles are needed. In most cases, a 50 percent aisle space saving is achieved versus single-deep selective rack. However, we cannot assume that a 50 percent true space savings will be achieved because we can only anticipate a 70 to 75 percent utilization of the available openings (due to honeycombing). (80 to 85 percent utilization ia common for single deep racking.)

Double-deep racks are typically used when the storage requirements for a SKU is five pallets or greater and when product is received and picked frequently in multiples of two pallets. (Assigning SKUs with only a single pallet on-hand to double-deep racking is nonsensical because one of the two positions in a facing is automatically wasted.)