RCPA: The Australian Pipe Company

RCPA aspires to be the supplier of choice and market leader in stormwater pipe & associated precast products. The corporate values are communicated as First, Family, Inclusiveness & Innovation, Responsible & Results, Safety & Sustainability and Technically Excellent.

The History

In 1995 the vertical dry cast pipe manufacturing process was brought to Australia and adapted to produce steel reinforced concrete pipes for the Australian market. Following a period of expansion Reinforced Concrete Pipes Australia Pty Ltd (RCPA) was formed in 2009 as a result of the merger between Reinforced Concrete Pipes (RCP) and Australasian Pipeline & Pre-Cast (APP). This merger resulted in the only national supplier of wall steel reinforced concrete pipe that is vertically cast and solely Australian owned and operated.

In 2015, RCPA acquired the fibre-reinforced concrete pipe division of James Hardie. Now known as FRCPipes, this product range extension gives RCPA a unique product offer including a range of specialty drainage systems across Australia.

RCPA has plants located in Sydney, Melbourne, Brisbane & Perth as well as partnering with local leading civil precasters in Adelaide, Canberra, Tasmania and Darwin. RCPA are focused on tailoring our product or service to individual customer needs, big or small. The commitment to exceeding expectations is paramount to the success of RCPA.

Capability

Service is in RCPA DNA. From RCPA people to RCPA technology and processes, the company truly believes that they service customers like no-one else can. The manufacturing processes utilize methods that enable to produce dependable quality products in the shortest possible time so that RCPA can keep customers and their projects on track.

Compliance goes hand-in-hand with all of our processes. RCPA maintains an ISO9001 certified QMS and runs a strong EH&S program focused on the health and safety of our people. The design and manufacture of products is required to meet local, state and national regulations, standards and specifications.

RCPA has the capacity to design, manufacture and supply customized:

Pipes,

Stormwater Systems,

Culverts,

Precast,

Columns.

The Process

RCPA’s vertically cast concrete pipe manufacturing process begins with a cage placed in the steel mould. The assembled mould is placed on a turntable and rotated into position beneath the bi-directional compaction head. Concrete is batched on site and fed directly into the pipe machine. Concrete compaction is achieved using counter-rotating rollers and steel finishing trowels which produce an accurate and straight bore with a high-quality finish. Compaction is continuously monitored for consistency.

Cage positioners ensure correct alignment of the reinforcing cage within the pipe wall. Every spigot is made using the same machined former which ensures that all spigots are identical. The one-piece spigot former eliminates the traditional problems with rough grout feathering at joints. Once cast the pipe is immediately stripped and placed onto the production floor. After curing, the pipes are inspected, branded, and delivered to the stock yard.

Steel Reinforced

RCPA steel reinforced concrete pipes exceed market standards. Australian thin walled concrete pipes leave little room for error in cover requirement, therefore RCPA wall thickness is deliberately designed to give more than adequate cover. RCPA pipe wall thickness are deliberately designed to provide cover to steel in excess of the 10mm AS4058 requirement. This provides enhanced steel protection, therefore increasing pipe durability.

A continuously welded reinforcement cage (including socket and spigot) is fabricated to fine tolerances. The cover is precisely maintained by form-mounted pneumatic cage positioners that minimize the need for plastic/steel spacers. To confirm the cover, pipes are routinely tested physically and with a cover meter.

High Technology Machinery

During COVID in 2021 RCPA decided to invest a new turn-key batch plant, specially dedicated to the production of concrete pipes with very tight quality controls, highly controlled environments under rigid production standards and testing specifications.

Along the years major investments in high technology machinery by RCPA has created a significant alternative supplier to those producers using traditional spun pipe and precast production in Australia. The constant drive for innovative products and processes, RCPA not only incorporates many production efficiencies of the “dry cast method” but also minimizes environmental impact and the usage of power in its factories throughout Australia. A faster, more flexible and efficient manufacturing process allows RCPA to offer shorter lead times and a very responsive customer service.

Concrete and Yatala Upgrade

RCPA produces concrete in fully automated batch plant that incorporates world-class moisture sensing and correction technology. This method ensures consistent concrete of the highest standard and a product which is extremely durable. The concrete mix is specially designed for the process and uses a very low water to cement ratio, also known as zero slump concrete, which permits instant de-moulding. Test results indicate typical compressive strengths in excess of 50MPa. General purpose cement is typically used, however specialty cements can be used for specific applications if required.

The batch plant upgrade of the Yatala factory is the outcome of a successful engineering project between RCPA and MCT technical Departments where:

new equipment has been integrated with existing parts;

very restricted available footprint has been perfectly used;

challenge win during erection with limited space available.

The engineering allows to re-use the existing of 30 m3 drive-over receiving hopper where the trucks discharge their materials and these are then taken via a new feeding belt to the aggregate storage hoppers. A special diverter installed at the end of the belt can feed the existing 30 years old batch plant and the new aggregates bins supplied by MCT.

The materials are then distributed into the correct compartment through a reversible shuttle belt, and all of these functions are controlled by the MCT Aggregate Feeding system, which runs independently from the main control system.

No. 4 Aggregate hoppers with a capacity of 40m3 each, 160m3 in total, receive the materials that are monitored via laser probes to ensure the precise volumes are both checked for materials used and materials being properly discharged when filled from the aggregate feeding system.

When a mix is called, the materials are collected by MCT’s Aggregate weigh batcher and discharged into the skip hoist. The aggregates dosing high precision is guaranteed by extracting belts instead of gates: through conveyors the constant flow of the material is always regular and the accuracy is extremely high.

The ‘skip hoist’ then takes the materials to the 3000/2000 planetary mixer, which provides the factory with the concrete through no. 2 inclined belts; a third gate in the mixer allows an easy discharge of washing water and rejected batch. Upon the mixer platform are the normal components such as Cement Weighing, Water distribution, Admix & dust extraction. Cement is fed from No. 3 of 80TON each to the mixer.

The mixer is washed via MCT’s own deigned washing heads and all the washed water and materials are gathered below the plant where they are separated and this water is recycled back into the plant, the waste material can also be recycled.

Why chose RCPA Pipe?

Neil Kingan, Group Manager – Capital Projects and Assets affirms: “Technology is core to our business which enables us to deliver an experience you won’t get anywhere else. RCPA pioneered the vertical dry-cast SRC pipe process in Australia and today we are the only supplier offering this product range throughout the country”.

Jesse Jackson, Capital Projects and Assets Engineer continues: “Our precast product technology and range is ever growing and offering our clients a diverse range of options for culverts, pits, headwalls and associated products”.

Flagship Project for MCT in Australia

Mr. Gabriele Falchetti, VP Business Development for MCT Italy, pointed out: “RCPA’s highly specified concrete is being supplied to meet the project‘s stringent requirements via a purpose-built precast batch plant at Yatala. MCT Italy is honored to have been selected to build a lasting legacy that will support Queensland development, creating economic opportunities and greatly improving the daily lives of many people”.

“Our flexible designs of batching plants and concrete distribution systems ensures the optimal solution for every process with the best utilization of space and the great performances with regard to safety and concrete delivery to the precast machines. Our long-term experience with almost all the precast machinery suppliers facilitates the project development through our technical departments for the best design of the whole precast factory. We will infuse and adopt new technology and integrated traceability system into this old industry, in order to make it relevant for the future”, he concluded.