Membrane Rack

Short Product Introduction

Membrane racks serve as the structural backbone and fluid distribution hub for industrial Ultrafiltration (UF), Reverse Osmosis (RO), and Membrane Bioreactor (MBR) systems. Built from heavy-gauge structural steel or aluminum, each rack anchors high-pressure vessels, integrates feed/concentrate manifolds, and maintains exact alignment under dynamic operational loads up to 1,200 PSI, with regional design adaptations engineered specifically for harsh Middle Eastern high-salinity desalination projects and stringent North American municipal seismic compliance.

Large Reverse Osmosis System
A reverse osmosis (RO) membrane rack is the core bearing and fixing device of reverse osmosis water treatment systems. It is mainly used to install and support RO membrane elements and pressure...
Ultrafiltration Membrane System
An ultrafiltration (UF) membrane rack is the core bearing and fixing device of ultrafiltration water treatment systems. It is mainly used to install and support UF membrane modules (including...
Stainless Steel Membrane Rack
A stainless steel membrane rack is a membrane module bearing device with 304/316L stainless steel as the core material. It is specially designed to fix and support membrane elements/modules such...
Carbon Steel Membrane Rack
A carbon steel membrane rack is a membrane module bearing device made of Q235 carbon steel as the base material, with the surface treated by epoxy spraying, rubber lining, or anti-corrosion coating.

Key Features

Load-Tested Structural Framing:

Finite Element Analysis (FEA)-verified frame design withstands dynamic hydraulic thrust, seismic forces (up to Zone 4 / IBC 2024 compliance), and wet operating weights.

Corrosion-Resistant Options:

Prefabricated in 304/316L Stainless Steel, Super Duplex (2205/2507), or Hot-Dip Galvanized Carbon Steel with multi-coat epoxy systems rated for extreme marine brine exposure (up to 80,000 ppm TDS common in Gulf region projects).

Integrated Header Manifolds:

Factory-aligned piping headers (HDPE, Stainless Steel, or Super Duplex) minimize field welding and pressure drop across the membrane train.

Vibration Isolation Pads:

Heavy-duty EPDM/Neoprene isolation mountings dampen high-pressure pump harmonics and prevent joint stress.

Modular Skid Architecture:

Pre-engineered containerized or skid-mounted configurations reduce site installation time by up to 60%.

How the Product Works

The membrane rack physically supports arrays of membrane pressure vessels while distributing feed water and collecting permeate and concentrate stream flow. Process fluid enters through the lower feed header, flows parallel or series across the vessel network, and exits via dedicated discharge headers. The structural frame absorbs torque, fluid momentum changes, and thermal expansion forces, preventing axial movement that damages membrane interconnectors and Victaulic couplings.

Product Selection Guide

Define Fluid & Environmental Chemistry: Select 304SS for municipal freshwater, 316L for brackish water, and Super Duplex 2205 / 2507 or structural steel with C5-M marine coating for high-temperature Middle Eastern seawater brine.

Determine Operating Weight & Load Limits: Calculate total wet weight including filled vessels, headers, valves, and live hydraulic force. Match against plant floor load limits and local seismic acceleration parameters.

Select Piping Header Interface: Choose Grooved (Victaulic), Flanged (ANSI/DIN/AWWA), or Socket Weld connections based on system design pressure ratings.

Validate Transport Constraints: Verify frame dimensions against standard ISO container sizes (20ft/40ft High Cube) or flat-rack shipping limits for international site delivery.

Technical Specifications

Specification	Standard Rating / Option
Structural Frame Material	Carbon Steel (A36/A572), 304/304L SS, 316/316L SS, Aluminum 6061-T6, Super Duplex
Frame Surface Coating	Hot-Dip Galvanized (ASTM A123), Polyurethane, Marine C5-M Epoxy System
Header Piping Options	Sch 10/40 Stainless Steel, Super Duplex 2205, HDPE SDR 11, Sch 80 PVC/CPVC
Pressure Class Support	Up to 1,200 PSI (83 bar) for SWRO systems
Weld Quality Standards	AWS D1.1 (Carbon Steel), AWS D1.6 (Stainless Steel), ASME Section IX certified
Dimensional Tolerances	Frame Squareness: +/- 2 mm; Header Centerline Alignment: +/- 1.5 mm

Typical Applications

Seawater Reverse Osmosis (SWRO)

Middle East Desalination: High-density Super Duplex racks engineered for high ambient temperatures and 1,000+ PSI operations in coastal Gulf plants.

Municipal Infrastructure

North American Upgrades: Seismic-compliant vertical racks designed to meet local building codes for municipal drinking water and wastewater reuse plants.

Industrial Wastewater Zero Liquid Discharge (ZLD)

Corrosion-proof heavy-gauge frames carrying high-recovery BWRO and EDR vessels.

Semiconductor Ultrapure Water (UPW)

Polished 316L SS cleanroom-compatible racks with orbital welded headers to prevent particle contamination.

Engineering & Customization

3D CAD & FEA Validation: Custom structural modeling using ANSYS to simulate static weight, dynamic fluid surge, seismic displacement (Zone 4 / IBC), and wind load.

Header Manifold Tailoring: Customizable port center-to-center distances, drop-leg angles, and instrument tap integration (NPT/Flanged).

Footprint Optimization: Custom tier stacking height and side-by-side spacing tailored to existing plant floor plans or containerized mobile units.

Manufacturing & Quality Control

Material Traceability:

Full Mill Test Reports (MTRs) provided per EN 10204 3.1 for all structural profiles and piping elements.

NDT Weld Testing:

100% Visual Inspection (VT) plus Dye Penetrant (PT) or Radiographic Testing (RT) on pressure-retaining and load-bearing welds.

Dimensional Inspection:

Laser tracker verification of mounting hole locations and vessel support cradle parallelism.

Factory Acceptance Testing (FAT):

Hydrostatic header testing at 1.5x design pressure for 30 minutes before surface coating.

Installation / Integration Considerations

Foundation Anchoring: Requires pre-installed chemical anchor bolts into reinforced concrete; shim sets provided for level tolerances up to 5mm.

Thermal Expansion Clearance: Header piping connections must incorporate grooved flexible couplings or expansion loops to isolate thermal movement from vessel ports.

Lifting & Rigging Points: Certified overhead lifting lugs positioned according to center-of-gravity calculations for safe crane unloading at international job sites.

FAQ

Q: What structural frame materials do you recommend for high-salinity Middle East SWRO applications?

A: For aggressive Middle Eastern SWRO applications, we recommend Super Duplex 2205 or 2507 for long-term resistance to pitting and crevice corrosion caused by high chloride concentrations and elevated seawater temperatures (brine streams up to 80,000 ppm TDS). Carbon steel frames with a certified C5-M heavy-duty epoxy coating system are available as an alternative for structural framing outside direct spray zones.

Q: How do you prevent galvanic corrosion between stainless steel headers and carbon steel frame structures?

A: We isolate dissimilar metals using high-density dielectric isolation pads (EPDM or PTFE) and non-metallic sleeve/washer sets at all contact points, structural clamps, and bolt assemblies. This prevents direct metal-to-metal contact and stops galvanic cell formation.

Q: What dimensional tolerances do your membrane racks maintain to prevent pressure vessel misalignments?

A: We manufacture frames to strict tolerances: structural overall squareness within +/- 2 mm, and header port center-to-center alignment within +/- 1.5 mm. This precision prevents radial force strain on Victaulic flexible couplings and stops O-ring extrusion at vessel end-cap connections.

Q: Can these racks be manufactured to fit standard 40-foot High Cube shipping containers?

A: Yes. Modular skids are designed around ISO shipping dimensions. A standard 40ft HC container accommodates skid modules up to 11.8m length x 2.25m width x 2.5m height, allowing direct roll-in/roll-out loading without specialized flat-rack freight surcharges.

Q: What weld certifications and testing standards apply to your rack manufacturing?

A: All structural welders are certified to AWS D1.1 (Carbon Steel) and AWS D1.6 (Stainless Steel). Piping headers are welded by ASME Section IX certified technicians. Quality control includes 100% visual inspection (VT), dye penetrant testing (PT) on load-bearing joints, and hydrostatic pressure testing at 1.5x design pressure on all manifold headers.

Q: How do you account for thermal expansion in long multi-vessel rack headers?

A: We integrate grooved flexible pipe joints (e.g., Victaulic style) at engineered intervals along the header line, combined with slotted anchor guides on the vessel cradles. This layout absorbs linear expansion and contraction without transferring axial force to the vessel end caps.

We're well-known as one of the leading membrane rack manufacturers and suppliers in China. With a professional production team, we are able to meet the needs of the majority of our customers. Please feel free to buy high quality membrane rack from our factory.

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