For decades, concrete was the default. Today, RPC’s GRP (Glass Reinforced Polymer) maintenance shafts are transforming the industry with faster installation, superior corrosion resistance, and significantly longer service life.

At RPC, we’ve been leading this shift for over 20 years. These GRP shaft structures can be installed in days rather than weeks, reducing traffic disruption, labour costs, and on-site safety risks. Their corrosion-resistant laminate construction performs far better than concrete in aggressive sewer environments, while remaining lightweight and structurally robust for deep installations. Factory-controlled manufacturing ensures consistent quality, with integrated vortex structures, drop pipes, and structural liners delivered ready to install.

Designed for a 100+ year asset life, our Australian-engineered GRP solutions offer a durable, low-maintenance, and future-proof alternative to traditional construction.

The PermaManhole liner

Designed exclusively by RPC engineers, the RPC PermaManhole is a semi-structural GRP manhole liner with an integrated channel liner with an O-ring seal. Eliminating the need for in-situ placement of reinforced steel in mass concrete encasement, the RPC solution minimises man-entry requirements and work in confined spaces.

Once the channel liner is installed and the joint tested, the GRP manhole liner can be installed, supported by a steel support frame at ground level.

Epping GRP Perma-Manhole liner (composite image)

Integrated off-site manufacture

Working with you to properly define the scope of your requirements, RPC can design, manufacture and deliver the PermaManhole structure that will present the easiest installation method. Our factory installs manhole liner ancillaries such as vortex structures, drop pipes, support clamps and ladders, so the complete assembly only needs to be dropped into place once delivered to site.

Maribyrnong 4m GRP maintenance shaft module delivered on a trailer

Rapid site installation, minimising risk and disruption

One-piece delivery minimises public interruption and significantly reduces installation time. Work health and safety risk is also minimised by avoiding the need for site personnel to access the manhole cavity during installation.

Our liners provide structural formwork that is capable of being placed into the excavations as a single or multi-piece segment and continuously concrete-encased in a single pour process.

Large GRP structure being finished by a worker on an elevated platform

Advantages

  • Unsurpassed corrosion resistance and a low-maintenance asset life of up to 100 years
  • Extraordinary temperature resistance, suitable for use with applications over 65°C
  • GRP in-situ cast-in-place formwork resists both short-term construction loads and long-term hydrostatic ground water pressure
  • An integrated design for one-piece manhole, drop pipe and channel invert liner delivery
  • Significantly reduced site risks and public disruption due to ease and speed of installation
  • Potentially eliminates the need for reinforcing steel in the manhole base

Adopted by

  • Yarra Valley Water
  • Melbourne Water
  • Queensland Urban Utilities
  • Brisbane Water
  • Sydney Water
  • Watercare NZ

Reference projects

  • Central Interceptor, Auckland: nine GRP cascade shafts, 3m–7.5m in diameter (2020–2025)
  • Maribyrnong Main Sewer Upgrade (Melbourne Water / SFPJV): 4m × 38m maintenance shaft (2022–24)
  • Epping Main Sewer Upgrade (Yarra Valley Water / JHG): 2 × DN3200 and 2 × DN4000 PermaManhole liners, 38–40m deep (2019)
  • Bulimba Creek Sewer Upgrade Stage 2 (QUU / Abergeldie–Obayashi JV): PermaManholes (2017)
  • Also Hobsons Bay Sewer Upgrade, Amaroo Sewer Main, Carlton Sewer Upgrade and Princes St manhole upgrade

Specifications

PermaManhole at a glance

Design standards
BS EN 13121.3:2008+A1:2010 and AS3571.1 (ISO 10467)
Off-site manufacture
1m up to 6m in diameter, in our purpose-built facility in Geelong, Victoria
Large-diameter shafts
Engineered and manufactured up to 7.5m in diameter
Placement
Placed and concrete encased within 24 to 48 hours
Temperature
Suitable for applications over 65°C (the hydration temperature of concrete)
Integrated features
Vortex structures, drop pipes, support clamps and ladders installed in our factory

Customer story

Australia's leaders in GRP maintenance shafts

Most people never think about maintenance shafts, yet they're some of the most critical structures in our sewer networks. They enable safe access for maintenance, ventilation, and inspection and they must withstand decades of chemical exposure, groundwater pressure, and structural loads.

Talk to the experts.

Tell us about your project and we’ll connect you with the right sector team.