Double Deck Trailers | Maximise Capacity & Efficiency

Q: What are Double Deck Trailers?

Articulated HGV trailers with two internal load platforms that increase pallet capacity. A standard build typically carries 52 UK pallets; LST builds can carry up to 60. They are most effective when volume rather than weight is the limiting factor, reducing trips, cost per pallet and emissions.

Q: How many pallets fit on a double deck?

A standard 13.6 m double deck typically carries 52 UK pallets (26 upper, 26 lower). LST builds can carry up to 60, subject to specification and bay compatibility.

3D Render | Curtainsider Double Deck In Showroom

Don-Bur Double Deck Trailers help UK fleets cut trips, boost capacity and reduce operating costs. As the UK’s leading supplier to major blue-chip operators, our trailers are engineered for optimal load fill, lower unladen weight and long-lasting strength — delivering better value throughout their service life. Options include pallet-network deckers, fixed decks (with tail-lift options), ratchet decks and hydraulic lifting decks — all tailored to your operation.

Key facts: A standard double deck typically carries 52 UK pallets (compared with 26 on a single deck). LST variants can carry up to 60, subject to route and bay compatibility.

Don-Bur has been designing and manufacturing double deck trailers since the 1980s and is the UK’s recognised market leader, supplying high-volume builds for the country’s largest fleets. Every trailer batch is engineered and built to order — matching load dimensions, minimising unladen weight to maximise payload, and integrating the latest in safety, access and sustainability technologies.

We are delighted that by working in partnership with Don-Bur and TIP we have developed a trailer that meets our operational, safety and environmental needs. It gives us greater efficiency whilst reducing our impact on the environment.

Ian Keilty, Chief Executive Officer, Whistl

Features

Don-Bur is the UK’s most experienced manufacturer of double deck trailers. Every build is engineered to deliver maximum capacity, efficiency and long-term value.

Optimised load fill: deck and body geometry custom engineered to your load profile for higher utilisation.
Lighter tare weight: advanced design and materials reduce unladen weight to increase payload capacity.
Flexible decking systems: choice of Fixed, Ratchet or Lifting decks in any configuration.
High capacity: carry up to 52 UK pallets (or 60 with LST builds).
Proven durability: robust chassis and bodywork designed for high-mileage trunking, reducing downtime and maintenance costs.
Safe, fast access: interlocks, controls and tailored apertures that protect operators and speed up loading.
Tail-Lift options: The addition of a two-tier tail-lift facilitates loading or unloading from the top deck.

Capacity & Efficiency

Double deck trailers offer up to 100% more pallet space compared with a single deck. A typical build carries 52 UK pallets, cutting delivery frequency and lowering cost-per-pallet. LST variants can carry up to 60, subject to specification and bay compatibility. The result is fewer trips, reduced mileage and lower fleet emissions.

“The investment in our fleet is part of the infrastructure upgrade the business requires to support growth. However this is also an opportunity to ensure drivers are equipped with the latest technology to ensure their safety and that of the public.”
— DHL

M&S Step-Frame Lifting Deck Trailers Plan A

Deck types at a glance

Fixed Double Deck Trailers

A permanent second floor for consistent load heights and trunking routes. Lightweight, reliable and cost-effective for predictable payload profiles.

Lifting Deck Trailers

A hydraulically raised upper platform loaded at dock height, then lifted to create space beneath. Increases bay flexibility and reduces turnaround times.

Ratchet Deck Trailers

A forklift-operated, multi-position upper deck. A robust, low-complexity solution for mixed SKUs where hydraulics aren’t required.

Wedge Double Deck Trailers

Straight-through floors with extra internal clearance — ideal for PPT use, tall pallets and roll cages.

Urban Double Decks

Compact geometry for city centre and retail park deliveries. Available as curtainsider or box, with your chosen deck system.

Special Types of Double Decks

For complex operations and atypical load profiles, Don-Bur engineers bespoke double deck solutions that work within site constraints, aperture limits and handling methods. We configure chassis geometry, deck mechanisms and access systems to fit your operation — not the other way round.

Chassis engineering: independent suspension and drop-frame layouts to optimise deck heights and loading apertures while maintaining stability and manoeuvrability.
Advanced mechanisms: butterfly decks, revolving decks and removable/sectional uppers for irregular or out-of-gauge items.
Access & integration: tailored rear/side apertures, compatible tail-lift configurations and restraint options for safe, efficient handling.
Duty-cycle validation: specifications proven for high-mileage trunking and repeated dock cycles, with reliability and uptime front of mind.

If your operation has unique constraints, our engineering team can configure a double deck solution to suit.

Box Van Independent Suspension Fixed Double Deck Trailer

Key Dimensions

The following table provides typical sample dimensions (m) and pallet footprints (UK) for a number of standard double deck trailer types.

Dimensions are approximate and are subject to enhancements and final engineering confirmation.

For these estimates, a fifth wheel height of 1.25m is assumed.

Split apertures (Lower/Upper) can vary depending on desired deck position. For instance, increasing lower deck aperture by 100mm will proportionately reduce upper deck aperture by 100mm.

"Apertures" are considered to be side apertures for curtainsiders and internal apertures for box vans.

Key dimensions and UK pallet capacity for double deck trailer types
Body Type	Length × Height	Chassis Type	Deck Type	Wheel size	UK Pallets	Aperture Height: Swan-Neck	Aperture Heights: Main (Lower/Upper)
Curtainsider	13.7 × 4.92	Step-Frame	Fixed to rear 2/3	19.5″	44	3.35	1.815/1.815
Curtainsider	13.7 × 4.92	Step-Frame	Fixed Full Length	19.5″	52	1.415	1.815/1.815
Curtainsider	13.7 × 4.92	Step-Frame	Lifting to rear 2/3	19.5″	44	3.35	1.8/1.8
Curtainsider	13.7 × 4.92	Step-Frame	Lifting Full length	19.5″	52	1.385	1.785/1.785
Box Van	13.6 × 4.92	Step-Frame	Fixed Full Length	19.5″	52	1.567	1.879/1.879
Box Van	13.6 × 4.92	Step-Frame	Lifting Full Length	19.5″	52	1.579	1.891/1.891
Box Van	13.6 × 4.92	Step-Frame	Lifting Full Length	17.5″	52	1.504	1.966/1.966
Curtainsider	13.7 × 4.92	Straight-Frame	Lifting Full Length	22.5″	52		1.6/1.6

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FAQs

What are Double Deck Trailers?

Articulated HGV trailers with two internal load platforms, designed to double pallet capacity. A standard build typically carries 52 UK pallets; LST builds can carry up to 60. Double deck trailers are widely used for national trunking and the distribution of light-to-medium weight goods. They are most effective when volume — not weight — is the limiting factor, cutting delivery trips by up to 50%, lowering cost per pallet, reducing emissions and improving overall fleet efficiency.

How tall are double deck trailers?

Most UK double decks run between 4.88 m and 4.95 m overall height, depending on route risk assessments, site clearances and operator policy. Internal deck heights vary by trailer type and specification.

Find out what the optimum double deck height is

How many pallets fit on a double deck?

A standard 13.6 m double deck typically carries 52 UK pallets (26 upper, 26 lower). LST builds can carry up to 60, subject to specification and bay compatibility.

Find out exactly how many pallets you can fit onto your trailers

What is a step-frame, swan neck or goose neck?

A step-frame (also called a swan or goose neck) lowers the main deck height behind the kingpin. This improves internal headroom and allows double-deck configurations with better clearances.

Step-Frames explained

Legally, what is the biggest trailer in the UK?

The standard semi-trailer length is 13.6 m. Longer Semi-Trailers (LSTs) are now permitted up to 15.65 m, but only under approved routes and operating conditions.

What payload weight can I carry on a trailer?

Payload depends on gross vehicle weight limits, trailer design and bodywork options. Double decks are usually volume-limited rather than weight-limited, as their capacity is driven by pallet count more than mass.

Discover what governs payload weight and how much you can load