Loading a double deck truck trailer

The double deck trailer is a practical answer to two key challenges in road transport: the necessity to carry a large volume of non-stackable goods and the need to maximize cubic capacity when transporting light, voluminous cargo.

This system allows for loading up to twice the number of pallets, eliminating the cost and time associated with an extra trip. However, implementing this solution requires precise planning due to the raised center of gravity and strict load limits per beam. In this article, we explain exactly what a Double Deck is, what the rules for safe loading of a double deck truck are, and how modern tools, such as the Goodloading load planning software, minimize the risk of operational error.

What is a double deck system?

The double deck system is a set of movable beams secured in special guides or rails inside the trailer, creating a second loading surface. The double floor can be set at various heights, adjusting it to the height of the cargo on the lower level.

This solution is particularly useful for non-stackable goods. Creating a second level of cargo effectively allows for the transport of twice the volume of goods.

When to use a double deck trailer?

Transport of non-stackable goods: Not all goods can be stacked, mainly due to the pressure exerted when loading subsequent layers of cargo. The Double Deck solves this problem by giving each pallet its own stable platform.
Maximum space utilization for light cargo: If the goods are light but take up a significant amount of space, the Double Deck allows for the maximum utilization of the trailer’s volume (cubature).

How to load a double deck trailer?

The process of loading a double deck truck is slightly more demanding. Firstly, the introduction of beam assembly/disassembly and loading on two levels extends the work on the ramp. The key challenge also concerns physical limitations: the standard system has a specific maximum load capacity per beam, which requires precise pallet placement to avoid exceeding the structural load limit.

Equally important is a strategic approach to weight distribution. Using a double deck raises the trailer’s center of gravity. This means that concentrating heavier pallets exclusively at one end of the vehicle, or only on the upper deck, worsens the vehicle’s stability during transit.

Finally, it is essential to remember a fundamental rule: the second floor does not increase the truck’s payload capacity, only its loading volume (cubature). The trailer itself, with the Double Deck system installed, is generally 500-800 kg heavier than the standard version. This reduces the available cargo limit, so this additional system tare weight must be taken into account when planning the load to avoid exceeding the Maximum Permissible Mass.

Double deck loading with the Goodloading planner

Planning the load for a double deck trailer can be a challenge, especially if the goods being transported have varied dimensions. In such a situation, the Goodloading load planning software proves invaluable:

Planning the load for a double deck: When adding a trailer in Goodloading, you can include the Variofloor (i.e., the double deck). You then specify its height from the floor, thickness, and maximum load capacity.
Visualization of cargo distribution: The next step is to add the cargo, which Goodloading automatically distributes within the available space.
3D load analysis: The completed load plan is visible in a 3D visualization. You can manually adjust the placement of the cargo and check data about the prepared project, such as the total weight of loaded goods, unused area in m², available/utilized volume in m³, occupied and free LDM (loading meters), and axle load distribution (if the user has added this to the program).
Load plan instructions: The finished project can be downloaded as a PDF file or a link and forwarded to the person responsible for loading. The warehouse worker or driver receives a 3D plan that minimizes the risk of human error and shortens loading time.

Would you like to check how many extra pallets you can fit into a double deck trailer? Register for Goodloading: https://app.goodloading.com/en/auth/register.