SECTION 02534

CAST IRON MANHOLE COVERS AND GRATINGS

PART 1 - GENERAL

1.01 SUMMARY

A. This Section specifies the manufacture, painting and installation of cast iron covers and gratings and
includes, but is not limited to, the following:
1. Manhole covers
2. Cover Locks
3. Multi-part covers
4. Cast iron gratings
5. Surface boxes
6. Sealing plates
7. Coating application
8. Cover Installation

B. Floor gratings, floor plate, access covers and roof hatches will be found in Section 05500.

1.02 RELATED SECTIONS

A. Section 01330 - Submittals

B. Section 01400 - Quality Assurance/Quality Control, Inspection and Tes ting
C. Section 01600 - Materials and Equipment
D. Section 02630 - Storm Water Drainage Systems
E. Section 05500 - Metal Fabrications
F. Section 06610 - Glass Reinforced Plastic Fabrications
G. Section 07920 - Sealants

1.03 REFERENCES

A. Product manufacture, testing and installation shall comply with the following references, unless
otherwise stated in the specifications or unless otherwise approved by the Engineer.
1. EN 124 -Gully and manhole covers
2. BS 2789 - Specification for spheroid graphite or nodular graphite cast iron
3. BS 2494 - Materials for elastomeric seals for joints in pipe work and pipelines.

1.04 DEFINITIONS

A. The following definitions shall pertain to words or phrases as utilised in this section.
1. “DI” shall mean ductile iron.
2. “CI” shall mean grey cast iron.
3. “Heavy duty” shall mean EN 124 Class D400.
4. “Medium duty” shall mean EN 124 Class B125.
5. “Light duty” shall mean EN 124 Class A15.

1.05 GENERAL REQUIREMENTS

A. Covers shall typically be utilised as follows, unless noted otherwise on the drawings or unless
approved otherwise by the Engineer.
1. “Non-rocking, heavy duty covers” shall be used in paved traffic areas.
2. “Medium duty covers” may be used in service corridors or unpaved areas.
3. “Light duty covers” may be used in pedestrian and non-traffic areas.

B. Size and configuration shall be as shown on the drawings, unless otherwise approved by the
Engineer.

C. Badging shall as a minimum include the following information:

1. Manufacturer’s name
2. Standard of manufacture
3. Loading class or grade
4. Type of material, “CI” or “DI”

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 5. Size
6. Service in English and Arabic

D. Castings shall be smooth, true to pattern and free from projections, sand holes, blow holes or other
distortions.
E. All covers and frames shall be coated under the Engineer’s supervision.
F. Contractor shall supply one prying and lifting bar of approved design with each 20 covers (minimum
of one tool for each type of cover).
1. Prying and lifting bars shall be of approved appropriate design to ma tch the different cover
configurations.

G. Push fit sealing plates shall be provided for all covers exposed to sewage or sewage gases.
H. Cover locks shall be installed on all sewer manhole covers.

1.06 SUBMITTALS

A. All covers and gratings shall be submitted for approval according to Section 01330.
B. Different types of covers, even if from the same manufacturer, should be placed in separate
submittals.
1. Covers of different sizes, but of the same type, may be placed in the same submittal.

C. As a minimum, the submittal should include the following.

1. Manufacturer’s name and product data
2. Standard of manufacture
3. List of sizes
4. Class or load rating
5. Material: DI or CI
6. Proposed service (sewage or storm water)
7. Shop drawings, showing badging and other details
8. Recent load test from independent laboratory
9. Recent metallurgical analysis from foundry

D. Coating application should be submitted separately and should include the following.
1. Name of coating and manufacturer’s product data.
2. Name of applicator and method statement for application.

E. Sealing plates (if required) shall be submitted separately and should include the following:
1. Name and product data on fabricator.
2. List of materials to be utilised and origin of manufacture.
3. Method statement for fabrication.
4. Shop drawings showing all details.

1.07 QUALITY ASSURANCE/QUALITY CONTROL

A. Prior to application of coatings, the Contractor shall notify the Engineer, in sufficient time to allow
the Engineer or his representatives to inspect the covers, if so desired.
1. All notifications shall be made by written “Inspection Requests” in accordance with Section
01400.
a. An advance copy may be faxed to the Engineers office, but the original must arrive before
the scheduled day of inspection.

2. Minimum notification times shall be as follows:

a. 72 hours for areas within Kuwait
b. 3 weeks outside of Kuwait.

B. Covers shall be sampled at random by the Engineer and load tested under his supervision, according
to EN124 procedures at the following rates.
1. For manufacturers operating under certified ISO 9000 Quality Procedures, the sampling and
testing rate shall be 1%.
2. For manufacturers not operating under certified ISO 9000 Quality Procedures, the sampling and
testing rate shall be at least 2%.

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1.08 DELIVERY, STORAGE AND HANDLING

A. Coated covers and frames shall be delivered, handled and stored according to the manufacturer’s
recommendations along with the following provisions:
1. Transportation, handling and storage shall at all times be performed in a manner to avoid
product damage, including the coating.
2. Only nylon slings shall be allowed for lifting covers and frames. Steel chains, clamps or cables
shall not be allowed for lifting purposes.
a. Steel chains or cables may be allowed for securing covers during transport or storage
provided protective padding or timber blocking is utilised.

3. Protective padding or timbers shall be placed between stacked covers.

4. Visually inspect all covers upon delivery and report any damage to the Engineer.
a. Any covers or coating damaged during delivery, storage or installation shall be marked and
set aside.
b. Proposals for repair of any damaged covers or coating shall be submitted in writing to the
Engineer for approval.
c. No repairs to damaged covers shall be attempted without the Engineer’s approval.
d. Any damaged covers deemed unsuitable for repair by the Engineer shall be removed form
site and replaced at the Contractors expense.
5. GRP sealing plates shall be stored in closed containers or out of direct sunlight, until needed.

PART 2 - PRODUCTS

2.01 MANHOLE COVERS AND GRATINGS

A. Standard manhole covers and gratings shall be manufactured and tested according to EN124, unless
stated otherwise herein, or unless otherwise approved by the Engineer.
1. Heavy duty and medium duty covers and gratings shall be made of ductile iron complying with
ISO 1083 Grade SG 500-7.
2. Light duty covers and gratings may be grey cast iron complying with BS 2789 requirements.
B. All covers for sanitary sewerage service shall be single piece.
1. Double triangular covers are not allowed on sanitary sewerage facilities.
2. Vented sanitary cover includes 20mm diameter holes, 6 Nos. @ 172mm from centre of cover or
as shown in Project Drawings.
3. Non vented sanitary cover do not include holes to allow air ventilation.

C. Covers and gratings shall have machined surfaces, to prevent rocking due to traffic.
D. Covers to be utilised for sewerage service shall have frames suitable for push fit sealing plates.

2.02 SURFACE BOXES

A. Shall be ductile iron conforming to BS 5834, Grade A loading.

B. Size shall be as shown on the drawing or as approved by the Engineer.
C. Other properties shall be as specified for manhole covers and frames.

2.03 MISCELLANEOUS CASTINGS

A. Storm Water Gutter

1. Heavy duty, ductile iron, single piece construction complete with bearer bars.
2. Conform to BSEN 124, Class D400 loading.
3. Gutter clear opening 240mm, or as shown on the Drawings.

B. Channel Grating
1. Heavy duty, ductile iron, single piece construction complete with bearer bars.
2. Conform to BS EN 124, Class D400 loading.
3. Cover clear opening 300 mm, or as shown on the Drawings.

C. Solid Top, Channel Covers

1. Heavy duty, ductile iron construction.
2. Conform to BS EN124, Class D400 loading.
3. Cover clear opening 300 mm, or as shown on the Drawings.

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2.04 COATINGS

A. All castings shall be locally coated by an approved applicator under the Engineer’s supervision.
1. All covers and frames shall be grit blasted to Sa 2.5 (near white metal) condition.
2. Coating shall be solvent free polyamine epoxy, applied in 2 coats.
3. Nominal dry film thickness shall be 400 microns (total), with no more than 10% of the thickness
readings less than 400 microns and no single reading less than 300 microns.

2.05 SEALING PLATES

A. Sealing plates shall be manufactured according to Section 06610 “Glass Reinforced Plastic
Fabrications” and as described below.
1. Sealing plates for manholes, chambers and sump access covers shall be GRP.
2. The sealing plate thickness shall be a minimum of 7mm and the minimum design load –
7.5kN/m².
3. The underside of the plate shall be protected with a resin rich vinlyester liner 1.5mm thick,
reinforced with glass tissue.
4. Isopthalic resin may be used in the structural wall.
5. All glass shall be ECR or other corrosion resistant type.
6. The sealing plate shall incorporate a peripheral rubber ring retained in such a manner that when
pushed into the access opening, a tight seal will be formed between the plate and the manhole
cover frame.
7. The plate and rubber ring shall be designed such that a watertight seal is obtained without the
use of bolts.
8. The rubber rings shall be made of EPDM rubber formulations, compliant with applicable
sections of BS 2494.
a. Ring joints shall be vulcanised.

9. The sealing plates shall have two securely laminated GRP lifting handles.
10. Cuts and /or drilled faces shall be sealed with resin.
11. Sealing plates shall be such as to allow installation of the manhole cover locks.

2.06 GROUT

A. Grout if required shall be a cementitious type and shall conform to the requirements of Section
03600.

2.07 SEALANTS

A. Sealants, if required, shall conform to the requirements of Section 07920.

PART 3 - EXECUTION

3.01 INSTALLATION OF STANDARD MANHOLE COVERS AND GRATINGS

A. Manhole covers and gratings shall be installed as shown on the drawings, unless otherwise approved
by the Engineer.
1. Frames for covers in paved traffic areas shall rest on a concrete screed or concrete block, with
the covers set flush with the road surface.
a. Cover must be secured by cover locks.
b. Cover lock bolts shall be coated with “Never Seize” prior to installation.
2. Frames in unpaved areas shall be cast or grouted into the concrete cover slab.

3.02 SURFACE BOXES

A. Surface boxes shall be cast or grouted into the concrete cover slab.

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