In short: FRP (composite) manhole covers are much lighter than cast iron, do not rust, and have little scrap value, which deters theft. Cast iron covers are heavy, proven and available for the highest load classes. In Europe and many other markets, covers are classified under EN 124. Classes run from A15 (pedestrian areas) to F900 (aircraft pavements). Composite covers are covered by EN 124-5, which applies to classes A15 to D400. That means composite covers can be specified for footways, car parks and carriageways, but not for the E600 and F900 classes used in docks and airports. The right choice depends on the installation location, the load class and local requirements. FIBROVX supplies FRP manhole covers to the class and size you specify, confirmed by the test data for that design.
EN 124 load classes
EN 124-1:2015 defines load classes by where the cover is installed.
| Class | Test load | Typical location |
|---|---|---|
| A15 | 15 kN | Pedestrian and cycle areas only |
| B125 | 125 kN | Footways, pedestrian areas, car parks and car parking decks |
| C250 | 250 kN | Curb-side channels, extending at most 0.5 m into the carriageway |
| D400 | 400 kN | Carriageways of roads, hard shoulders and parking areas for all types of road vehicles |
| E600 | 600 kN | Areas with high wheel loads, such as ports and dock sides |
| F900 | 900 kN | Areas with especially high wheel loads, such as aircraft pavements |
The class must suit the most demanding load the cover can see, not the usual one. A cover on a footway next to a road where trucks may mount the curb needs a higher class than one in a garden.
EN 124-5: composite covers
EN 124-5:2015 is the part of EN 124 for gully tops and manhole tops made of composite materials. It is used together with EN 124-1, never on its own. Its scope sets these conditions:
- Products: manhole tops and gully tops made of composite materials C1, C2 and C3, with a clear opening up to and including 1000 mm, covering gullies, manholes and inspection chambers in areas used by pedestrians and/or vehicles.
- Manufacturing: the products must be made "by using suitably controlled automatic processes that produce a single structure and that do not contain multiple pieces bonded together". A cover or grating assembled from several bonded parts is outside the scope.
- Not covered: tops made by the hand lay-up method, gratings and covers of prefabricated drainage channels (EN 1433), floor and roof gullies in buildings (EN 1253), and surface boxes.
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Load classes:
- A15: areas used only by pedestrians and pedal cyclists.
- B125: pedestrian and comparable areas, car parks and car parking decks.
- C250: curbside channels, extending up to 0.5 m into the carriageway and up to 0.2 m into the pedestrian area, measured from the curb edge.
- D400: carriageways of roads (including pedestrian streets), hard shoulders and parking areas for all types of road vehicles. In EN 124-5, D400 applies to manhole tops only, not gully tops.
- Not included: classes E600 and F900 are not covered by EN 124-5.
- Marking: products are marked with EN 124-5, the class, the manufacturer's name or mark, the place of manufacture and the date of manufacture, among other items.
Note on FIBROVX and EN 124-5: FIBROVX manufactures composite covers by two processes: controlled automatic single-piece molding and hand lay-up. Covers made by the controlled automatic process can be produced to EN 124-5, provided the cover meets all of the conditions above; conformity is confirmed per order and per load class, backed by load test results for that design. Hand lay-up covers are outside the scope of EN 124-5. They are supplied to the requirements specified for your project, with load testing to those requirements, confirmed per order. This note is not a claim of certification, CE marking or third-party marking. If your project requires those, state it in your inquiry and we will confirm what can be provided for that order.
Cast iron covers are covered by EN 124-2. Other countries use their own standards, for example AASHTO M 306 in the United States. Tell us the standard your project requires.
FRP vs cast iron at a glance
| Factor | FRP composite cover | Cast iron (ductile or gray) cover |
|---|---|---|
| Weight | Much lighter for the same opening | Heavy |
| Handling | Easier, lower manual-handling risk | Often needs lifting keys or equipment |
| Theft | Low scrap value deters theft | Scrap value attracts theft |
| Corrosion | Does not rust | Can rust and corrode |
| Load classes (EN 124) | A15 to D400 under EN 124-5 | Up to F900 |
| Electrical | Non-conductive | Conductive |
| Cost | Depends on class and size | Depends on class and size |
Weight and handling
Lighter covers reduce manual-handling risk for maintenance crews. Lighter covers still need correct seating and, in traffic areas, locking or a design that keeps them secure.
Theft deterrence
Metal covers are stolen for scrap. An open manhole is a serious hazard. Composite covers have low scrap value, which removes that incentive.
Corrosion
In sewers, coastal areas and chemical plants, cast iron can corrode. FRP does not rust.
Electrical
FRP covers are non-conductive, which is useful in utility and telecom chambers.
When cast iron is the better choice
- E600 and F900 locations, such as docks and airport pavements, which are outside the scope of EN 124-5.
- Where a client or authority specifies metal.
- Very heavy, frequent traffic where the specifier prefers a proven metal cover.
Manhole covers vs tank and basin covers
Manhole covers are trafficked access covers set in frames at ground level. Covers over open wastewater tanks and basins are a different product: they enclose the tank to contain odors and are usually not designed for vehicle loads. See FRP wastewater tank covers for that application. For long, narrow runs of covers over cable or service trenches, see FRP trench covers: load classes and selection, which covers run layout, cover length and the EN 1433 drainage channel case.
How to specify a manhole cover
- Location and load class. Choose the class for the most demanding load.
- Clear opening and frame size. Give the opening and the frame dimensions.
- Shape. Round, square or rectangular.
- Standard and marking. For example EN 124-5 class D400.
- Locking and hinges. Specify if needed.
- Surface and logo. Anti-slip pattern, text or logo.
- Quantity and destination.
Customization
FIBROVX manufactures FRP manhole covers to order. We can adjust size, shape, class, color, surface pattern, logo and locking. The load class is confirmed by the test data for that design. Ask us for it before you order. See also the Tanks, Pipes and Covers collection.
Need a quote or a drawing check?
FIBROVX manufactures FRP products in our own factory in China and builds every item to order: sizes, resin system, color, molds and OEM branding. Send your application, dimensions or drawing, quantity and destination port.
Request a QuoteCommon mistakes
- Choosing a class for typical, not worst-case, traffic.
- Specifying composite for E600 or F900 locations.
- Ignoring the frame. The frame and seating matter as much as the cover.
- Not asking for test evidence. Ask for test data for the class.
- Confusing tank covers with manhole covers.
Key terms
- Clear opening: The diameter or size of the opening through the frame.
- Load class: EN 124 classification based on test load and location.
- Test load: The load a cover must withstand in the standard test.
- Composite: A material made of fibers in a resin matrix, such as FRP.
Watch: FRP Manhole Covers vs Cast Iron in 27 Seconds
FAQ
Can FRP manhole covers take vehicle traffic?
Composite covers can be designed and tested to EN 124-5 class D400, which covers carriageways. Check the class of the specific design.
Are FRP manhole covers lighter than cast iron?
Yes, much lighter for the same opening, which eases handling.
Why are composite covers used to prevent theft?
They have little scrap value, so there is no incentive to steal them.
Which EN 124 part covers composite covers?
EN 124-5:2015, for classes A15 to D400 (D400 for manhole tops only), used together with EN 124-1.
Do FRP covers rust?
No.
Can you add our logo?
Yes. Send the artwork with your specification.
Related guides
- FRP Septic Tanks Guide
- FRP Storage Tanks Guide
- What Is FRP?
- Technical Resources: datasheets and drawings on request
- FRP for Wastewater Treatment Plants: Covers, Grating and Odor Control by Plant Area
- FRP for Telecom Infrastructure: Cable Supports, Covers and Marker Posts
- EV Charging Stations: FRP Cable Trench Covers, Bollards and Cable Supports
- Emerging industries we serve
- FRP Trench Covers: Load Classes and Selection
Sources
- CEN, EN 124-1:2015 Gully tops and manhole tops for vehicular and pedestrian areas, Part 1: Definitions, classification, general principles of design, performance requirements and test methods (CEN standard; available from national standards bodies)
- CEN, EN 124-5:2015 Gully tops and manhole tops, Part 5: Gully tops and manhole tops made of composite materials (CEN standard; available from national standards bodies)
- EN 124-5:2015 scope and abstract (iTeh Standards catalog, CEN/TC 165): https://standards.iteh.ai/catalog/standards/cen/63143102-a6e9-459f-aca8-05bd336df9d8/en-124-5-2015
- BSI Knowledge, BS EN 124-5:2015 (scope and exclusions): https://knowledge.bsigroup.com/products/gully-tops-and-manhole-tops-for-vehicular-and-pedestrian-areas-gully-tops-and-manhole-tops-made-of-composite-materials
- CEN, EN 124-2:2015 Part 2: Gully tops and manhole tops made of cast iron (CEN standard)