Double Deep Pallet Racking Supplier & Exporters for Brazil

The standardized Brazilian pallet (PBR-1) measures 1000mm in width by 1200mm in depth, with a bottom deck board arrangement distinct from European EUR-EPAL (800x1200mm) and American GMA (40x48 inches) specifications. In double deep racking, pallets are stored with their 1200mm depth facing into the rack bay. To securely support the bottom boards of two consecutive PBR pallets, upright frames are fabricated with custom structural cross-ties, and bay beam lengths are generally configured at 2300mm (for two pallets side-by-side) or 3400mm (for three pallets side-by-side), ensuring minimum 75mm side clearances per ABNT NBR 15524 regulations.

Standard counterbalance forklifts cannot service double deep configurations. Warehouses must deploy pantograph-type reach trucks (equipped with a hydraulic scissor extension mechanism) or reach trucks fitted with telescopic forks (forks that hydraulically extend into the second pallet depth). Pantograph trucks are the most prevalent in Brazil (supplied by manufacturers like Hyster, Yale, Crown, and Toyota), generally operating in aisle widths between 2.9 and 3.2 meters, with mast lift capacities up to 9.5 meters while maintaining residual stability.

In Brazil, state fire safety instructions (such as Instrução Técnica nº 25 in the State of São Paulo) mandate unobstructed vertical flue spaces to allow early sprinkler activation (ESFR - Early Suppression Fast Response) and heat venting. Double deep racks place four pallets back-to-back across two double runs. Our engineering drawings provide verified minimum 150mm longitudinal flue spaces and 100mm transverse flue spaces, complete with heavy-duty pallet back-stops, guaranteeing that pallet placement cannot encroach into the sprinkler penetration zone.

Yes, high-strength galvanized wire mesh decking is strongly recommended for double deep systems, especially on higher beam tiers. In pharmaceutical, cosmetic, and food distribution centers regulated by ANVISA (Agência Nacional de Vigilância Sanitária), wire decking prevents dust and debris accumulation, improves ambient lighting in deep bays, prevents loose boxes from falling between beams, and satisfies sanitary requirements that prohibit solid wood shelving prone to biological contamination.

Because double deep reaching operations generate elevated dynamic mast oscillations and eccentric foot loads through upright baseplates, the industrial concrete floor slab should have a minimum thickness of 180mm to 200mm, with a compressive strength of fck ≥ 30 MPa (reinforced with welded wire mesh or steel fibers). Floor flatness should conform to ASTM E1155 F-numbers (FF ≥ 45 / FL ≥ 35) or DIN 18202 Table 3 Line 4 to avoid mast sway when positioning pallets on upper levels (above 7.5 meters).

Production lead times for custom-engineered double deep projects typically range from 25 to 35 business days depending on tonnage. Ocean transit times to major Brazilian ports—principally the Port of Santos (São Paulo), Port of Paranaguá (Paraná), Port of Itajaí/Navegantes (Santa Catarina), and Port of Suape (Pernambuco)—span approximately 32 to 40 days. We provide advance container packing lists, fumigation certificates (ISPM 15 compliant for timber dunnage), and Bill of Lading documentation for pre-clearance with Brazilian customs brokers.

ABNT NBR 15524-2 dictates visual and documented inspection procedures for steel racking systems in Brazil. We provide localized bilingual (English/Portuguese) load rating plaques (Placas de Capacidade de Carga) to be affixed to each aisle end. We recommend daily visual checks by warehouse operators, weekly supervisor inspections, and an annual formal structural survey by a qualified structural engineer to assess beam deflection limits (L/200) and identify column upright damage classified under Green, Amber, or Red risk zones.

Absolutely. Double deep is one of the most cost-effective structural systems for cold storage warehouses operating between 0°C and -28°C across Brazil's meat, poultry, and dairy export regions. Cold storage buildings incur immense refrigeration energy costs per cubic meter. By reducing the number of operating aisles, double deep optimizes refrigerated airspace. For extreme humidity or sub-zero environments, we provide hot-dip galvanized components or special low-temperature epoxy powder formulations that maintain impact ductility and resist flaking.

Yes, our systems are designed on modular European and ABNT-compliant hole matrices. If your SKU profile shifts in the future toward higher selectivity (demanding 100% direct access), double deep runs can be disassembled and re-spaced as single selective runs by adjusting aisle widths. Alternatively, if volumes demand full automation, the upright frames can be retrofitted with galvanized support rails and guide channels to accommodate Automated Radio Shuttle cars, protecting your long-term capital investment.

To produce an optimized structural layout and export commercial proposal, our engineering team requires: (1) Warehouse architectural CAD/PDF drawing showing column grid spacing, dock positions, and clear ceiling height under roof trusses; (2) Pallet specifications including overall dimensions (W x D x H including cargo overhang) and maximum loaded weight; (3) Forklift model, maximum lifting height, and minimum aisle turning radius; and (4) Facility operating temperature and city/state location in Brazil for seismic/wind calculation adjustments.