April 29, 2025 Choosing the Right Access Covers: A Comprehensive Guide for Safety and Longevity
If you’re responsible for maintaining public spaces, overseeing building works, or simply trying to keep a site running safely and efficiently, you’ll already know how important the small details are. One of those often overlooked details is access covers. Whether it’s for routine inspections, drainage, or underground utilities, choosing the right cover can save you a lot of hassle later on.
In the UK, it’s not just about finding something that fits. Access covers need to hold up under heavy use and cope with everything from frost to floodwater, as well as meet BS EN 124 standards. Depending on location, a lightweight composite cover might be perfect, but on the other hand could be completely wrong. There’s rarely a one-size-fits-all all approach to access covers, so you’ll need to know what works and what won’t.
This guide walks you through what you need to know. We’ll cover materials, load ratings, and how access covers, manhole covers, and drain covers differ (and sometimes overlap). If you’re comparing options or planning an upgrade, this is a good place to start.
Understanding Access Covers
Access covers do a relatively simple job. But it’s important not to underestimate how important their role is. On the surface, they are simply just manhole covers or drain covers, but there are key differences in how they’re used and what they’re built for. An access cover is designed to sit flush with the surface and provide occasional or routine entry to services beneath, whether this be to inspect electrical wiring, communications ducts, water meters, or mechanical systems. In other words, it’s about safe, reliable access when you need it, without disrupting the surface or creating a trip hazard.
Manhole covers, on the other hand, are usually fitted over openings large enough for a person to enter. We see these most commonly in sewer or utility tunnels. Drain covers are typically part of water flow systems which are designed to prevent debris from clogging drains while still allowing water to pass through.
Materials & Load Ratings
Access covers come in a range of materials, each with its own strengths. Cast iron has long been the go-to for heavy-duty jobs since it’s tough, stable under pressure, and ideal for busy roads or industrial settings. The downside? It’s heavy and not always the most cost-effective option for smaller projects.
Galvanised steel on the other hand is a popular choice for its balance of strength and corrosion resistance. It’s lighter than cast iron and holds up well in both wet and dry environments. For areas exposed to the elements or chemical runoff, stainless steel is often preferred due to its hard-wearing, low-maintenance nature along with clean looks even after years of use.
Then there’s composite, which is gaining traction. It’s lightweight, non-conductive, and ideal for areas where manual handling is a concern. While not always suitable for high-traffic areas, it’s a smart choice for pavements, green spaces, or indoor applications.
As for load ratings, the BS EN 124 standard sets the benchmark in the UK. You’ll see covers classed from A15 (for pedestrian-only areas) right up to D400 (for roads and heavy traffic). Getting the right class for the job is crucial. If you accidentally under-spec, you risk damage or injury; over-spec and you may be paying for strength you don’t need.
Comparing Access Covers, Manhole Covers & Drain Covers
While the terms are often used interchangeably, there are some differences worth knowing, especially if you’re looking at specs for a new project or replacing damaged infrastructure.
Manhole covers are generally larger and heavier and are made to provide full-body access for inspections or repairs in sewer systems, utility tunnels, or telecom chambers. They’re built for strength and durability because they’re often installed in areas with high footfall or vehicle traffic.
Drain covers & solutions serve a different purpose. These sit over water drainage points and are designed to prevent debris build up while still allowing water to flow through. Drain covers are most commonly found in road gullies or surface water drains and are not usually intended to be removed frequently.
Access covers are more about convenience. They sit flush with the ground or flooring and are designed to give quick access to smaller chambers or service boxes without compromising safety. You’ll find them everywhere from car parks to plant rooms.
In some projects, you might need all three working together, particularly on larger commercial or municipal developments. Getting the distinctions right helps ensure long-term performance and compliance.
Selection Criteria & Best Practices
Choosing the right access cover starts with understanding the environment it’s going into. Outdoor covers need to cope with rain, frost, and sometimes chemicals, especially in industrial or coastal areas. Indoors, covers might need to blend into a finished floor or allow for frequent access without disruption.
Traffic matters too. Light pedestrian use is one thing, but if you’re dealing with delivery vehicles or forklifts, you’ll need something fit for purpose, both in terms of material and load rating. Slip resistance is another key factor in public spaces, especially near schools, hospitals, or high-footfall areas.
With access covers, it’s always best to think long term. A higher-quality cover might have a bigger upfront cost, but it often pays for itself through fewer maintenance issues and longer service life.
Installation Guidance
Installing an access cover isn’t complicated, but it’s important to get it right. Start by ensuring the base is level and compacted as an unstable foundation can lead to rocking or movement over time. Measure carefully and choose a cover that fits flush to avoid trip hazards.
If the cover’s heavy, use proper lifting gear or tools to avoid injury and always follow health and safety procedures. Once fitted, check that everything’s seated properly. There should be no rattling or movement, and it should take the weight it’s rated for without shifting.
Maintenance & Replacement
Even the best and most durable access covers need checking from time to time. Look out for signs of wear including rust, cracks, or loose fittings which can all affect performance. Clearing debris and checking fixings during routine site checks can help catch issues early.
If a cover is damaged or no longer fits properly, replacement is usually the safer, more cost-effective choice. Upgrading to a newer material, such as a composite or corrosion-resistant finish can also improve durability and reduce future maintenance.
Why the Right Access Cover Pays Off in the Long Run
Getting the right access cover isn’t just about ticking a box. It’s about keeping people safe, meeting UK health and safety regulations, and avoiding future headaches. Whether you’re comparing manhole covers, drain covers, or specialist access covers, the right choice can make all the difference in performance and longevity.
If you’re planning a project or need help choosing the best option, get in touch with Fabweld Steel Products. Our team is here to offer advice, answer questions, or provide a quote tailored to your site’s needs.