Since the 1980's Don-Bur has been designing, manufacturing and evolving double deck trailers in the UK to suit a wide range of customers looking to improve profitability and reduce their impact on the environment. With decades of specialist experience in this field, Don-Bur has become a recognised market leader and their products now dominate many of the UK fleets.
For transport operations that are limited by cubic capacity rather than by weight, the use of double decks generates a very real opportunity to increase fill per trip, therefore reducing trip frequency. By reducing the number of journeys required to move the same volume of freight, operators may be able to reduce fleet size, helping to lower costs associated with fuel, drivers, maintenance, tax and insurance.
Choosing the right double deck system
This page provides a high-level overview of the main double deck trailer systems available and the factors that influence specification. For detailed technical information, dimensions, operational considerations and example configurations, follow the links to the dedicated product pages below.
The main double deck trailer systems include:
- Fixed Decks
- Ratchet Decks
- Lifting Decks (moving decks)
Links are provided below to explore more detailed pages, giving greater insight into options, dimensions, weights, capacity and ultimately cost-effectiveness.
What are Double Deck Trailers?
Double deck trailers are articulated HGV trailers fitted with a second internal load platform, allowing goods to be carried on two levels within the same overall vehicle envelope. As trailer heights in the UK are unregulated and are only limited by practical bridge heights, this provides the facility to maintain the same load heights on each deck that you might otherwise find on shorter, single deck trailers.
The term 'Double Deck Trailer' covers both curtainsiders and box van bodies containing one of several deck system types (or a hybrid combination), including fixed, revolving, butterfly, ratchet and hydraulic lifting decks (sometimes referred to as moving decks).
Capacity and internal volume vary slightly between trailer and deck types. In terms of UK pallet footprint (1.2m x 1.0m), a standard single deck trailer can house a maximum of 26 pallets. In comparison, the same length double deck version can carry 52 pallets and an LST version can carry 60 pallets.
The key to matching double deck trailer specification to each customer revolves around the payload type, how it is loaded and whether it will carry out pure trunking work (primary distribution), secondary distribution or even last mile and urban deliveries.
Are double deck trailers suitable for all transport operations?
Double deck trailers offer the greatest benefit where available trailer volume becomes the limiting factor before legal weight limits are reached. This is particularly common within retail distribution, FMCG logistics, parcel carriers and pallet network operations.
As Europe generally imposes a trailer height limit of 4.0 m, double deck trailers are less common on continental operations unless load heights are relatively low. Likewise, operators carrying dense commodities such as steel, aggregates and paper are often constrained by payload rather than volume, making conventional single deck trailers a more suitable solution.
Don-Bur double deck trailers are now widely used across UK trunking, retail distribution, FMCG, parcel and pallet network fleets.
Fixed double deck trailers
Fixed double deck trailers use a permanent upper platform positioned at a constant height. They are suited to operations where pallet heights, loading patterns and route profiles are relatively consistent.
They are commonly used across trunking, pallet network, general haulage and retail distribution work, particularly where operators need predictable deck heights, robust construction and maximum load footprint within the available trailer envelope.
Fixed deck systems can be specified for curtainsider or box van bodywork, with the final layout influenced by loading method, pallet height, aperture requirements and any need for compatible tail-lift equipment.
Ratchet deck trailers
Ratchet deck trailers use mechanically adjustable upper deck sections, fitted to curtainsider bodywork. Each section can be repositioned to different heights using a forklift, making the system suitable for mixed pallet heights between trips.
Individual ratchet deck modules can also be incorporated into fixed deck layouts where additional loading flexibility is required.
Lifting deck trailers
Lifting deck trailers use a hydraulically operated upper platform that can be loaded at a practical working height and then raised to create load space beneath.
They are well suited to high-throughput operations where loading speed, bay efficiency and turnaround time are important. Options are available for both curtainsider and box van bodywork.
For curtainsiders, lifting deck systems can allow goods to be side-loaded at standard trailer height before being raised into position, helping avoid the need to load directly at upper deck height.
Other double deck configurations
Where operations start to differ from the norm, bespoke engineering may be needed to achieve the right balance of access, clearance, deck usability and payload efficiency.
- Urban double decks: shorter, manoeuvrable trailer layouts, often incorporating steering axles, can improve access to restricted urban delivery environments and store deliveries.
- Chassis geometry: straight-frame, step-frame, wedge and drop-frame chassis configurations can each be tailored to suit different load profiles, aperture requirements and internal height distribution.
- Custom deck mechanisms: butterfly, revolving or hybrid deck arrangements can be developed for unusual freight dimensions or specialist handling requirements.
- Tailored access systems: apertures, compatible tail-lifts and load restraint arrangements can be specified to suit the operating method.
Typical double deck trailer dimensions and pallet capacity
The table below outlines typical sample dimensions and UK pallet capacities for common double deck trailer configurations.
Dimensions are indicative and subject to final engineering confirmation. Further options are available.
Assumed fifth wheel height: 1.25 m.
Split apertures (Lower/Upper) vary according to deck position. Increasing lower aperture height proportionately reduces upper aperture height.
"Apertures" refer to side apertures for curtainsiders and internal apertures for box vans.
| Body Type | Length x Height | Chassis Type | Deck Type | Wheel size | UK Pallets | Aperture Height: Swan-Neck | Aperture Heights: Main (Lower/Upper) |
|---|---|---|---|---|---|---|---|
| Curtainsider | 13.7 x 4.92m | Step-Frame | Fixed to rear 2/3 | 19.5" | 44 | 3.35m | 1.815/1.815m |
| Curtainsider | 13.7 x 4.92m | Step-Frame | Fixed Full Length | 19.5" | 52 | 1.415m | 1.815/1.815m |
| Curtainsider | 13.7 x 4.92m | Step-Frame | Lifting to rear 2/3 | 19.5" | 44 | 3.35m | 1.8/1.8m |
| Curtainsider | 13.7 x 4.92m | Step-Frame | Lifting Full Length | 19.5" | 52 | 1.385m | 1.785/1.785m |
| Box Van | 13.6 x 4.92m | Step-Frame | Fixed Full Length | 19.5" | 52 | 1.567m | 1.879/1.879m |
| Box Van | 13.6 x 4.92m | Step-Frame | Lifting Full Length | 19.5" | 52 | 1.579m | 1.891/1.891m |
| Box Van | 13.6 x 4.92m | Step-Frame | Lifting Full Length | 17.5" | 52 | 1.504m | 1.966/1.966m |
| Curtainsider | 13.7 x 4.92m | Straight-Frame | Lifting Full Length | 22.5" | 52 | 1.6/1.6m |
FAQs
How tall are double deck trailers?
Most UK double deck trailers operate between 4.88 m and 4.95 m overall height. The exact height is governed by route risk assessments, site restrictions and the configuration required for the intended load.
How many pallets fit on a double deck trailer?
A standard 13.6 m double deck trailer typically carries either 44 UK pallets where the upper deck extends from the swan-neck rearwards, or 52 UK pallets where a full-length upper deck is fitted. Longer Semi-Trailers (LSTs) can increase capacity to up to 60 UK pallets.
Find out exactly how many pallets you can fit onto your trailers
What payload can a double deck trailer carry?
Payload is governed by plated weight limits, axle configuration and overall vehicle design. In many double deck operations, trailers are volume-limited rather than weight-limited, so usable capacity is often driven more by pallet count than by mass.
Discover what governs payload weight and how much you can load
What internal height clearances are available in double deck trailers?
Internal clear height depends on overall trailer height, floor height, deck thickness and deck position. The resulting usable height varies according to trailer design, deck configuration and the load profile the trailer is intended to handle.
What our customers say
"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."
"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."
Image gallery
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Peckover Distribution curtainsider trailer with fixed double deck and custom load restraint -
Screwfix tri-axle step-frame Lifting Deck trailer -
Ceva max cube Longer Semi-trailer with lifting deck -
Cutaway rear 3/4 view of Lifting Deck 'Adapt' trailer -
EH Taylor curtainsider double deck incorporating pneumatic step ramp -
Asda Moving Deck Trailer -
TIP Roche Curtainsider Lifting Deck -
Palletnetwork double deck curtainsider longer semi-trailer in Palletline livery -
Curtainsider double deck trailer with two-tier tail-lift (B&M livery) -
Front 3/4 view of Primark wedge LST with lifting double deck -
Double deck curtainsider trailer with ratchet deck modules and LoadFix load restraint -
Ratchet Deck With Bungee Load Restraint Straps -
TJ Morris box van trailer with fixed double deck and two-tier tail-lift -
H Parkinson ratchet double deck curtainsider trailer -
APC curtainsided double deck trailer with EcoStream roof (on motorway) -
UPS Lifting Deck trailer with straight-frame chassis -
Double Deck curtainsider longer semi-trailer in DX livery -
TDX straight-frame curtainsider trailer with full-length Lifting Deck -
Clipper Longer Semi-Trailer (Wedge design) with low fifth wheel height and full-length lifting double deck -
NHS Wedge Lifting Deck Trailer -
Curtainsided double deck trailer for the Palletnetwork Pallet Track -
M&S step-frame, lifting deck trailers in Plan A livery -
Gregory tri-axle double deck trailer with clearspan curtains -
Great Bear curtainsider double deck trailer with full-height side nets -
Maryland insulated curtainsider double deck including fridge -
Curtainsider double deck trailer with internal two-tier tail-lift -
B&Q double deck trailer with step-frame chassis and side-guard infill panels -
Pets At Home curtainsider double deck trailer with full-height side nets -
Curtainsider Double Deck Mesh Deck -
Curtainsider double deck trailer with clearspan curtains and central support posts -
Kuehne & Nagel curtainsider double deck trailer with fixed rear panel -
GXO Blade Panel Wedge Lifting Deck Trailer -
Yodel Lifting Deck trailer with aerodynamic EcoStream roof and side skirts -
UPS Wedge Lifting Deck Trailer -
The original M&S Wedge Lifting Deck trailer -
Cutaway view of a wedge Lifting Deck Trailer showing potential load fill -
Amazon straight-frame "Wedge" Lifting Deck Trailer with Blade panels -
DHL Blade Panel Lifting Deck Trailer -
DHL box van Lifting Deck trailer backed onto a bay -
Fixed double deck straight-frame trailer with side skirts in Allied Bakeries livery -
Rear 3/4 view of Whistl 'Wedge' Lifting Deck trailer incorporating Blade panels -
Whistl Lifting Deck Trailer with aerodynamic EcoStream roof profile -
Ratchet deck module being repositioned by forklift
Price range & availability
Price: P.O.A.
Available to pre-order
