GRP riser for the Alkimos Seawater Desalination Plant being lifted by crane

Sector

Infrastructure

Design, manufacturing, and installation of large-scale, bespoke GRP structures for civil, water/wastewater, energy, and mining projects.

Markets

  • Civil
  • Water & wastewater
  • Desalination
  • Energy
  • Mining

RPC prides itself on being able to meet the most demanding project time frames and solving and delivering complex engineering and manufacturing composite challenges.

From wastewater treatment plants to cooling water pipes, to desalination plants, RPC has decades of experience in the water and wastewater industries. Due to their resistance to corrosion and bacterial growth, lightweight nature, and long design life, GRP products are perfectly suited to water and wastewater applications.

Vent and exhaust stacks are covered under PermaVent® & PermaStack®, and mine ventilation under Mine Vent Ducting.

Advantages of GRP

  • Corrosion/chemical resistance
  • Extraordinary weight to strength ratio
  • Low maintenance
  • Fatigue resistance
  • Fire retardant
  • Electrical insulation
  • 50+ years of experience: one of the longest-standing specialist GRP contractors in Australia
  • Deep engineering capability for bespoke and engineered-to-spec projects
  • Long relationships with tier-1 civil contractors who return to RPC for major projects
  • Ahead of its field in technology and capability
GRP cascade shaftCentral Interceptor, May Road
7.5m × ~70m
GRP dome cover, 20m below sea levelBelmont Desalination Plant
15m
GRP spools pre-fabricatedAlkimos Desalination Plant
~1,100
GRP ducting, DN100–DN1200St Marys WRRF
1,750m

What we deliver

Six areas of work, each designed by our engineers, made in our own plants and, where needed, installed by RPC site teams.

01

Odour Control

RPC partners with AZZURO, technology partner for bio-trickling filters, to design, manufacture, deliver, install and commission complete odour control facilities.

  • St Marys WRRF (Sydney Water, AdaptJV), 2019–2024: 3 × AZZURO TR36-5 bio-trickling filters, 4 × RPC2650D activated carbon units, 1,750m GRP ducting, 1,500 m² of covers and a 1.2m × 18m GRP stack, treating 42,900 m³/hr of foul air. Australian Water Association Innovation Award finalist (2025).
  • Coombabah STP Stage 6 (Gold Coast, for Acciona), 2020: 3 bio-trickling filters, 800m foul-air duct and 600 m² of flat trafficable covers.
  • Sydney Water Major Periodic Maintenance (2026): assessing and optimising odour control facilities across multiple treatment plants, through Asset Services.
St Marys WRRF odour control facility — bio-trickling filters and ducting

AZZURO Puretta

Designed to provide efficient, inexpensive treatment of odours released from sewer manholes, pump station wells and smaller wastewater treatment plants. The Puretta range utilises the same Spacious Wire Pac [SWP] media used in AZZURO's larger Bio-trickling Filters.

  • Compact, pre-assembled system supplied ready to install.
  • Simple to install and easily relocatable.
  • Continuous reliable operation; minimal maintenance required.
  • An optional carbon polishing stage for sensitive locations.

AZZURO Torrenta

Designed to provide efficient, cost effective odour removal for large sewage pump stations and wastewater treatment plants, using AZZURO's patented Spacious Wire Pac [SWP] media.

  • Single pass irrigation system.
  • Eliminates the requirement for recirculation.
  • Significantly reduces instrumentation requirement resulting in smaller control panels.
  • Continuous reliable operation; minimal maintenance is required.

02

Piping

Filament wound GRP pipe, fittings and pre-fabricated spools for water and sewer works, power station cooling water, sea water intake, brine outfall and process piping for desalination plants, and process piping for the chemical industry.

  • Alkimos Desalination Plant (ASDP Stage 1), for the Alkimos Seawater Alliance: pre-spooling of approximately 1,100 GRP spools with around 4,000 butt strap and branch joints, DN25 to DN1600 (2026).
  • Alkimos: three GRP risers, 12–14m long × 1.8m ID, installed offshore in 12–20m of water (2025–26).
  • Keppel Sakra Cogen (600MW, hydrogen-ready), Singapore: GRP seawater cooling pipe up to 2.8m diameter (2024).
  • Sembcorp CCP4 (600MW), Singapore: main cooling water pipe up to 2.4m diameter (2024).
  • PT Amman Mineral Batu Hijau CCPP-1 (450MW), Indonesia: ~900m PN6 GRP pipe DN50–DN1100 with a full engineering package (2023).
  • Batang power stations, Central Java: 3.9m × 12.75m GRP cooling water pipes, 12km of pipe and fittings (2017).
GRP cooling water pipework, PT Amman Batu Hijau power plant

PermaGRE® pipe

RPC is an exclusive distributor of the PermaGRE® product range of high-pressure pipes and fittings made from glass reinforced epoxy resin, serving the mining, oil, gas, infrastructure, resources and energy markets in Australia and South East Asia. PermaGRE® high-pressure pipe is a non-corrosive product made by filament winding fibreglass saturated in a proprietary formula of epoxy resin and curing agents.

  • Line piping up to 3,600 PSI (25 MPa) continuous operating pressure.
  • Up to 93°C continuous operating temperature.
  • Deep hole capability to 1,500 metres with an operating pressure rating of 21 MPa.
  • No cathodic protection required.
  • Design service life from 25–100 years.

03

Covers

Self-supporting and trafficable GRP covers for tanks, clarifiers and ocean intakes.

  • Belmont Desalination Plant: 15m-diameter GRP dome cover for the direct ocean intake, operating 20m below sea level (2025–26).
  • Lower Molonglo WWTP (Icon Water): 20m self-supporting, perimeter-bolted GRP tank cover lifted in one piece (2020).
  • St Marys WRRF: 1,500 m² of trafficable aluminium (5kPa) and GRP covers.
  • Subiaco WWTP: covers and duct for John Holland.
Belmont desalination GRP intake cover segments

04

Shafts

GRP maintenance shafts and shaft liners are transforming the industry with faster installation, superior corrosion resistance, and significantly longer service life. They can be installed in days rather than weeks, and are designed for a 100+ year asset life.

Acting as in-situ cast-in-place structures, the liners are encased in concrete to create a corrosion-resistant shaft liner with no exposed concrete surfaces.

  • Yarra Valley Water, Melbourne Water, Queensland Urban Utilities, Brisbane Water, Sydney Water and Watercare NZ have adopted GRP for large-diameter access and maintenance shafts.
  • Central Interceptor, Auckland: nine GRP cascade shafts, 3m–7.5m in diameter (2020–2025).
  • Maribyrnong Main Sewer Upgrade (Melbourne Water): 4m × 38m maintenance shaft (2022–24).
  • Epping Main Sewer Upgrade (Yarra Valley Water): 2 × DN3200 and 2 × DN4000 PermaManhole liners, 38–40m deep (2019).
GRP PermaManhole liner being lowered into a shaft excavation

05

Tanks & Vessels

Large diameter bespoke GRP tanks, scrubbers and vessels for assets that need to work 24/7 in highly demanding and/or corrosive environments.

  • Kwong Cheong Thye, Singapore: 53 FRP tanks — 47 round, 2.5–3m in diameter and 6.5–17.5m high, plus 6 rectangular — made in Batam (2024–25).
  • BHP Whyalla (1998): two wet gas scrubbers 8.2m in diameter and 26m high, and an exhaust stack 3.8m in diameter and 100m high — the largest GRP structures ever manufactured in Australia.
45-year-old GRP aluminium sulphate tank under inspection

06

Ducting

GRP foul-air ducting, dampers and supports for odour control systems.

  • St Marys WRRF: 1,750m of GRP ducting, DN100–DN1200, with dampers, fans and instrumentation.
  • Coombabah STP Stage 6: 800m of foul-air duct.
Malabar wastewater GRP odour-control installation, 2012

Projects

Infrastructure projects

All projects
Rawalpindi shaft segment RW-07 ready for dispatch

InfrastructureAuckland, New Zealand · 2020–2025

Central Interceptor

Design, manufacture, delivery and installation of nine GRP shafts, 3m–7.5m in diameter, joined to the 16.2km wastewater tunnel, the largest wastewater project in NZ history.

GRP cascade and maintenance shafts
9
Shaft diameters
3m–7.5m
Depth of May Road shaft A
~70m
15m GRP dome cover for the Belmont desalination ocean intake, assembled on site

InfrastructureBelmont, NSW · 2025–2026

Belmont Desalination Plant

Scope, design, engineering, manufacture, delivery and site assembly of a 15m-diameter GRP cover operating 20m below sea level, for the direct ocean intake at Hunter Water's new desalination plant.

Diameter dome cover
15m
Below sea level
20m
Plant capacity, rainfall-independent
30 ML/day

Downloads

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