The XTRADECK double-deck system: the solution for doubling the cargo capacity of vans

In a context where optimizing transportation has become a major challenge, bodybuilders play a strategic role in designing increasingly efficient vehicles.

Forankra’s XTRADECK double-deck system has established itself as an essential solution for equipping box trailers (dry or refrigerated) and meeting carriers’ demands for productivity, profitability, and sustainability.

Thanks to this solution, it is now possible to significantly increase route efficiency while improving working conditions for operators and reducing environmental impact.

What is the XTRADECK double-deck system?

The XTRADECK system is a double-deck solution designed for vans and refrigerated vehicles. The concept is simple: add a second level of load-bearing beams inside the vehicle to double its cargo capacity. 

It consists of rails and beams to be installed in the van. The load-bearing beams slide along the rails attached to the vehicle walls, allowing the height and configuration of the load to be adjusted as needed. 

Why install a double floor in a semi-trailer?

Optimizing cargo volume is a key logistics concern. With a double-floor system, it becomes possible to utilize the vehicle’s full interior height.

The XTRADECK system thus allows you to:

• Double cargo capacity (up to 66 pallets instead of 33) 
• Safely transport non-stackable pallets 
• Reduce the number of trips required 
• Improve fleet profitability 

For a bodybuilder, this represents significant added value to offer to their transport customers.

A solution designed for logistics performance

Using the XTRADECK system offers several strategic advantages for carriers:

• Achieve cost savings through reduced fuel consumption.
• Help reduce emissions by cutting CO₂ emissions in half for the same volume of cargo.
• Improve operational efficiency: a single driver can make two trips with a single load. 

A modular system adaptable to different vehicles

The XTRADECK system is available in several configurations to accommodate vehicle-specific requirements, enabling bodybuilders to expand their product offerings:

DPA System: Surface-mounted installation

In this configuration, the rails are mounted directly on the van’s walls without modifying the structure. This solution is particularly well-suited for dry vans.

ATD System: recessed or semi-recessed rails

The ATD-F and ATD-2 versions integrate the rails into the vehicle’s sidewall, an ideal solution for refrigerated vans that optimizes usable width.

Certain configurations also comply with European hygiene directive 93/94/EEC for refrigerated bodies. 

Two load capacities to meet every need

The XTRADECK system is available in two main versions:

• XtraDeck Standard: load-bearing beam with a load capacity of 1,000 daN.
• XtraDeck Heavy Duty: load-bearing beam with a load capacity of 1,300 daN.

A design focused on ease of use

The system was designed to simplify loading and unloading operations.

Smooth and quiet operation

Thanks to their composite end caps, the tracks significantly reduce noise and improve ease of use.

Quick and Easy Handling

The beams are handled using a specially designed control rod that allows them to be positioned in no more than two movements, even when visibility is limited.  

This ergonomic design helps to:

•    Reduce musculoskeletal disorders (MSDs),

•    Improve working conditions,

•    And increase productivity.

Components of an XTRADECK System

A complete system typically includes the following components:

•    23 load-bearing beams (1000 daN or 1300 daN),

•    2 single rails,

•    22 double rails,

•    1 control bar,

•    46 beam stop rings,

A sustainable and recyclable solution

The XTRADECK system is primarily made of aluminum, a recyclable material. The use of recycled aluminum also helps minimize the product’s environmental impact.

This approach is part of a broader strategy aimed at reducing transportation-related emissions and optimizing logistics resources.

Why should you offer the XTRADECK double floor to your customers?

For a body shop, incorporating XTRADECK into your offerings allows you to:

• Stand out in a competitive market
• Offer a high-value-added solution
• Meet the specific needs of transport companies
• Generate projects with higher profit margins

Discover the XTRADECK double-floor system

Conclusion

The XTRADECK system offers an effective solution for professionals, enabling them to optimize the capacity of their vans. By adding a second modular loading level, it allows for the transport of more goods, improves productivity, and reduces the environmental impact of logistics operations.

By doubling loading capacity, optimizing costs, and improving operating conditions, it stands out as an essential solution for bodybuilders seeking to offer innovative and competitive vehicles.