Overview

Relevant across

  • Water
  • Wastewater
  • Mining
  • Chemical processing
  • Energy

Know how long your GRP assets will last — without shutting them down. We measure the wall’s health from the outside while your plant keeps running, and tell you how many years each tank, pipe and scrubber has left: no shutdown, no confined-space entry and no cutting samples.

GRP is no longer a difficult-to-assess material class. Together with UTComp — the global leaders in GRP asset condition research and creators of UltraAnalytix® — RPC has introduced inspection and assessment technologies that make GRP Asset Condition Assessment (Fitness-For-Service) as structured, repeatable and field-ready as conventional steel assessment frameworks.

RPC’s successful record of designing, engineering, manufacturing and installing major FRP assets for Governments and asset owners is unmatched in Australian and South East Asian markets, and we bring that knowledge to asset management. Customers using our Asset Services capability include Sydney Water, BHP and Veolia.

What asset owners gain

  • Standardise GRP condition assessment across their networks
  • Improve decision-making through consistent, defensible data
  • Shift from reactive maintenance to risk-based planning
  • Extend asset life while maintaining safety and performance
  • Sole Australian licensee of UTComp UltraAnalytix® — a non-destructive, data-driven method to assess the structural health of composite assets
  • A natural extension of RPC's design-and-manufacture work with the same clients
  • Contracts with Sydney Water
FRP tanks assessed for Sydney Water2026
68
Water Resource Recovery FacilitiesSydney Water, 2026
19
Estimated remaining service life of 45-year-old tanks2025 inspection
>6 years
Replacement cost deferred on those tanks2025 inspection
~$1.5M

What we deliver

RPC can test and inspect one asset, such as a tank or pipeline, or provide a strategic program of GRP/FRP testing and reporting for an entire facility — then plan, maintain and renew it.

01

In-Service Inspection

UltraAnalytix® is a world-first technology that enables condition assessments on GRP assets such as tanks, pipes and other structures whilst still operating. RPC will come to your site to test the integrity of your GRP assets while they are still operating, meaning no time is lost to shut-downs.

Damage to GRP starts in the resin, not the glass fibres, and is usually invisible until the asset leaks. The traditional way to look is to shut the asset down, drain and clean it, send someone inside and judge the surface by eye — or cut a sample out of the wall.

UltraAnalytix® works like a medical ultrasound for your tank. Our inspector places an ultrasound probe on the outside wall at set points; sound pulses echo back from every layer of the laminate, and damaged resin echoes differently — even when the surface looks fine. UTComp's engineers then analyse the readings against millions of data points from GRP assets worldwide.

  • Exclusive UTComp UltraAnalytix® licence for Australia, New Zealand and South-East Asia: first signed in March 2019 and extended for a further five years in February 2024.
  • Used by more than 300 asset owners worldwide in chemical processing, oil and gas, pulp and paper and mining.
  • Works on GRP/FRP, carbon fibre, dual laminate, HDPE and polypropylene.
  • Desalination RO pressure vessels (2022): RPC and UTComp tested 8 vessels from two desalination plants — more than 2,000 readings, checked against destructive tests. Damage began in the resin and was invisible before leaks. The research showed regular UltraAnalytix inspection could save the global desalination industry billions by reducing water losses and replacement costs.
UltraAnalytix ultrasonic probe reading on a GRP asset

How it works

Four steps, with no shutdown, no confined-space entry and no cutting samples.

  • Scan: our inspector places an ultrasound probe on the outside wall at set points.
  • Read: sound pulses echo back from every layer of the laminate, revealing hidden damage.
  • Analyse: UTComp compares the readings with millions of data points from GRP assets worldwide.
  • Decide: you get each asset's condition, damage depth and remaining life.

UltraAnalytix® vs traditional visual inspection

What changes when the inspection moves to the outside of the wall.

  • Your plant keeps running — no shutdown, draining or cleaning.
  • Tested from the outside — nobody goes in, nothing is cut.
  • Every layer is checked, right through the wall — not just the inner surface by eye.
  • Measured numbers — polymer damage, thickness, damage depth and Remaining Life (RL) — rather than an opinion two inspectors can disagree on.
  • The same points are re-measured next time, so you see the trend.

02

Condition Assessment

Reports give the asset's overall condition, structural integrity and Remaining Service Life (RSL), so asset owners can shift from reactive maintenance to risk-based planning.

The key measure is PDS (Polymer Damage Status), which scores the health of the resin that holds the wall together, starting at 100% when new. We track it over time and project it forward — when an asset reaches its critical PDS, its service life is up. Damage builds fastest when an asset is new, then slows, so an old asset can still have years of safe life left.

  • Sydney Water (2026): non-destructive evaluation of 68 FRP tanks across 19 Water Resource Recovery Facilities, with condition assessments and Remaining Service Life analysis — without shutdowns or confined-space entry.
  • 45-year-old tanks (2025): five 50,000L aluminium sulphate tanks at Sydney Water's Fairfield Wastewater Treatment Plant, originally built by Transfield RPC. They showed dirt, mould and coating cracks and looked due for replacement, but the lowest measured PDS was ~60% against a 40% critical threshold — Fit For Service (FFS), status CLEAR, estimated remaining service life >6 years. The client avoided unnecessary capital replacement, deferring about $1.5M.
  • Barwon Water (2026): appointed to a panel for FRP asset condition assessments and inspections — similar to the role RPC performs for Water Corporation WA.
45-year-old GRP aluminium sulphate tank under inspection

A clear verdict: Clear, Monitor or Hazard

Verdicts follow the colour-code criteria in UltraAnalytix® Mechanical Integrity Reports, based on a 3-year maximum inspection interval.

  • Clear: stays above the critical PDS for 6+ years. Re-inspect on schedule.
  • Monitor: could reach it in 3–6 years. Plan repair or replacement.
  • Hazard: has reached the critical PDS, or could within 3 years. Act now.

What's in your report

Every assessment comes with a report you can act on.

  • Quick summary: each asset's verdict at a glance.
  • Detailed check-up: corrosion barrier, structural layers, thickness and damage depth, point by point.
  • Remaining life: PDS projected forward to show when each asset reaches the critical PDS.
  • Photo guide: pictures of every issue we found, and where.
  • Action list: what to repair or replace, and by when.
  • Next inspection date: when to re-test, so you can track the trend.

Coming soon: API 579 Part 16

The first fitness-for-service standard written for composites is on its way. RPC has the GRP expertise, technology and capacity to assess your assets to this new standard across Australia, New Zealand and South-East Asia.

    03

    Repairs and Maintenance

    One partner for the whole life of your GRP assets. With 50 years designing and building GRP, RPC follows the inspection through — from planning the work to repairing, maintaining and renewing the asset.

    • Plan: maintenance strategy and renewal budget based on remaining life.
    • Maintain: planned, corrective and emergency repairs.
    • Renew: replacements designed and built by RPC Infrastructure.
    • Sydney Water Major Periodic Maintenance (2026): assessing and optimising Odour Control Facilities, including chemical scrubbers, across multiple treatment plants.
    Technician in PPE on a stepladder inspecting a GRP tank

    Projects

    Asset Services projects

    All projects
    RPC inspector testing a GRP asset, 2026

    Asset ServicesSydney, NSW · 2025–2026

    Sydney Water asset inspections

    UltraAnalytix® condition assessments and Remaining Service Life analysis of 68 FRP tanks across 19 Water Resource Recovery Facilities, without shutdowns or confined-space entry.

    FRP tanks assessed
    68
    Water Resource Recovery Facilities
    19
    Lowest PDS in the 45-year-old tanks (threshold 40%)
    ~60%

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