Double-Deep Racking System
The Akuros Double-Deep Racking System is designed for warehouses that need to increase pallet storage capacity without expanding the existing building footprint.
By storing pallets two positions deep, the system reduces the number of access aisles and allocates more warehouse floor area to pallet storage. It provides higher storage density than single-deep selective racking while maintaining forklift-based operation.
The system is best suited to warehouses with consistent pallet dimensions, stable loads, grouped SKUs and inventory flows that can accept LIFO or FILO access within each double-deep storage lane.
A suitable double-deep reach truck is required to access the rear pallet position. Rack depth, height, beam levels, aisle width and load capacity must therefore be designed together with the forklift’s lift height, reach distance, residual capacity and turning requirements.
Share your warehouse dimensions, clear height, pallet size, pallet weight, SKU quantity, target pallet positions and reach-truck information with Akuros before the final layout and structural configuration are confirmed.
Integrated Racking and Reach-Truck Engineering
Rack Layout and Equipment Matching System
The racking layout is engineered together with pallet data, warehouse dimensions and double-deep reach-truck performance.
Akuros reviews rack depth, beam levels, aisle width, lift height, reach distance, residual capacity and turning space as one coordinated system. This helps ensure that the rear pallet position can be accessed safely without creating unnecessary aisle width or operational bottlenecks.
Final dimensions and load ratings are confirmed through project-specific layout and structural calculations.
Reach-Truck Compatibility
A double-deep racking system requires a compatible deep-reach truck to access pallets stored in the rear position. Reach distance, lift height, residual capacity, aisle width and turning space must be reviewed together with the racking layout.
Akuros matches the rack depth and aisle configuration to the selected reach truck, helping reduce the risk of insufficient reach, restricted maneuverability or inadequate load capacity at the required storage height.
Higher Storage Productivity Within the Existing Footprint
More Pallet Positions, Fewer Aisles
Storing pallets two positions deep reduces the number of access aisles and allows more warehouse space to be used for pallet storage.
Planned Front and Rear Pallet Access
Front and rear pallet positions can be organized by SKU, batch or inventory rotation to support predictable storage and retrieval with a double-deep reach truck.
Scalable Warehouse Configuration
The modular frame-and-beam structure allows rack bays, beam levels and storage zones to be planned according to current capacity and future warehouse growth.
Storage Efficiency
Higher Pallet Storage Density
Storing pallets two positions deep reduces the number of access aisles and creates more pallet positions within the existing warehouse footprint.
Better Use of Warehouse Space
The double-deep layout allocates more floor area to storage, helping warehouses increase capacity without immediate building expansion or relocation.
Modular and Cost-Controlled Expansion
The frame-and-beam structure can be configured by bay, height and storage level, providing a scalable alternative to more complex automated storage systems.
System Safety & Operational Control
Uprights, beams, bracing and anchors are selected according to pallet weight, rack height, beam span and storage levels. Project-specific load calculations help maintain structural stability during long-term warehouse operation.
Rack depth, aisle width, turning space and storage height are coordinated with the selected double-deep reach truck to support controlled access to both front and rear pallet positions.
Upright protectors, end barriers, load signs and scheduled inspections help reduce impact damage and identify structural issues before they affect warehouse safety or daily operation.
Double-Deep Racking Applications
Cold Storage and Food Distribution
Double-deep racking helps refrigerated and freezer warehouses increase pallet positions inside costly temperature-controlled floor space.
It is suitable when products can be grouped by SKU, batch or expiry requirements and the inventory flow can accept planned front-and-rear pallet access.
Manufacturing and Batch Storage
Manufacturing warehouses can use double-deep racking for raw materials, packaging, components and finished goods with consistent pallet specifications and predictable batch movement.
Distribution and 3PL Warehouses
Distribution and third-party logistics facilities can use the system in storage zones where higher pallet density is more important than direct access to every pallet.
SKU grouping and access frequency should be reviewed carefully before assigning products to double-deep locations.
Double-Deep Racking Configuration Options
Upright, Beam and Storage-Level Options
Upright profiles, beam lengths, beam capacities and storage levels can be configured according to pallet dimensions, pallet weight, rack height and available warehouse clearance.
Pallet Support and Rack Protection
Depending on pallet quality and site requirements, available accessories may include pallet support bars, row spacers, upright protectors, end barriers, back stops and load identification signs.
Ambient and Cold-Storage Finishes
Surface treatment and corrosion-protection options can be reviewed according to indoor humidity, chilled storage, freezer conditions and the required service environment.
Interested in a High Capacity Reach Truck?
A representative from your local Solutions & Support Center will use the information you provide below to develop the best solution for you.