Optimizing Mushroom Cultivation Space: A Steel-Plastic Pipe Racking Solution

This case study presents a technical solution for implementing a comprehensive steel-plastic pipe mushroom cultivation racking system within a specific growing space measuring 33 meters in length and 15 meters in width. The goal was to maximize space utilization and create an efficient, durable infrastructure for mushroom production.

The Client's Need

The client required a robust racking system to fit within their 33m x 15m cultivation area. Key specifications included the need for 7 rows of racks, each 33 meters long and 2.8 meters high with 5 layers. The layer heights were specified with the bottom layer 0.3 meters from the ground and subsequent layers spaced 0.5 meters apart.

Our Engineered Solution

We designed a tailored racking system incorporating two different rack widths to optimize the use of the available space while ensuring structural integrity and ease of operation. The solution includes:

· Seven Rows of Racks: The design incorporates seven rows of mushroom cultivation racks running the length of the 33-meter space.

· Rack Dimensions: Each rack stands 2.8 meters high and spans the full 33-meter length of the cultivation area. The system features 5 layers, with the lowest layer positioned 0.3 meters from the ground and the four upper layers having a clearance of 0.5 meters each.

· Varied Rack Widths: To fit the 15-meter width of the space effectively, the solution includes:

o Two rows of wall-side racks, each 0.75 meters wide.  

o Five rows of center racks, each 1.2 meters wide.  

· Optimized Support Structure: The racks are designed with different numbers of longitudinal bars per layer to provide adequate support for the varying widths:

o Wall-side racks utilize 4 longitudinal bars per layer.  

o Center racks utilize 6 longitudinal bars per layer.  

o Upright sets are spaced at 1.94-meter intervals along the length of each row, with 18 sets of uprights per row.  

· Integrated Aisleways: The layout includes 1-meter wide aisles between each row of racks. These aisles are crucial for providing clear paths for access and operations within the cultivation space. Aisle bars connect the uprights of adjacent racks, enhancing the overall structural stability of the system.  

· Enhanced Stability: Additional support is provided by diagonal braces. Each set of uprights includes 2 diagonal braces, contributing to the rack's stability. Across the length of each 33-meter row, there are 12 diagonal braces strategically placed.  

· Durable Materials and Components: The racks are constructed using high-quality materials:

o Uprights are made from carbon steel plastic-coated square tubes (30x50x1.3 mm).  

o Upright braces and longitudinal bars are made from steel plastic-coated round tubes (25x1.0 mm).  

o The system utilizes high-quality nylon components and plug-ins, ensuring simple assembly and long-lasting durability.  

· Significant Load Bearing Capacity: The racking system is designed to handle a substantial load, with a capacity of 120-150 kilograms per square meter per layer.  

· Efficient Space Utilization: The entire racking system occupies a total area within the cultivation space measuring 13.5 meters in width and 33 meters in length. A 0.75-meter distance is maintained between the wall-side racks and the end walls.  

Packaging and Delivery

For transport, the main pipe components are sorted and bundled. These bundles are then securely wrapped with stretch film and strapping. The completed packages are entrusted to a professional logistics and freight company for delivery.