Manhole covers and frames are an essential feature of our urban and industrial infrastructure, protecting access points to underground utilities such as sewerage, drainage and telecommunications systems. However, lifting and moving these covers can present a range of challenges, from physical strain to logistical difficulties. This article explores the types of manhole covers, the risks of handling them manually, and the equipment available to make the job safer and more efficient.
Types of Manhole Covers and Their Handling Challenges
Manhole covers come in various materials, sizes and designs, each of which presents specific challenges during handling. Cast iron covers are among the most commonly used due to their durability and strength. However, they are also incredibly heavy, often weighing more than 50 kilograms, making manual handling difficult and risky.
Composite manhole covers, on the other hand, are made from lightweight materials like reinforced plastic or resin. While they are easier to manage due to their reduced weight, careful lifting techniques should still be used to avoid injuries.
Steel and aluminium covers provide a middle ground, offering strength with moderate weight, but their large, flat shapes can still make them awkward to handle manually.
Concrete covers, frequently used in industrial or heavy-duty settings, are the heaviest of all and present significant challenges.
Moving these covers without specialised equipment is almost impossible. In addition to their weight, many covers fit tightly into frames to prevent water ingress or tampering, making them even harder to lift without mechanical assistance.
Health and Safety Risks of Moving Manhole Covers
Lifting manhole covers manually without proper techniques or tools can lead to both immediate and long-term health problems. One of the most common risks is back injuries caused by the heavy lifting required. Manhole covers often need to be moved from awkward positions, forcing workers to adopt postures that strain their lower back muscles. If this is done repeatedly, it can lead to chronic pain or even more serious issues like herniated discs.
There is also a significant risk of crush injuries. A slipping manhole cover can easily trap fingers or toes, causing serious damage. Strains and sprains are another concern, particularly when workers are forced to use excessive force to lift a stuck cover. This can affect the shoulders, wrists, or knees and the risk increases when the ground is wet or uneven, making stability more difficult.
Over time, poor manual handling practices can lead to repetitive strain injuries or chronic musculoskeletal disorders, which may reduce a worker’s mobility or ability to work altogether. Employers must take these risks seriously, as failure to provide safe working conditions can result in both health complications for employees and legal repercussions for the organisation.
How Much Does a Manhole Cover Weigh?
Due to the fact they’re typically made from concrete, cast iron or in some cases both, you can expect a manhole cover to easily weigh over 100kg, but this will vary depending on the size. The reason for their extreme weight is they need to be sturdy enough that they can cope with vehicles passing over them and also so that they’re resistant to theft.
How to Lift a Manhole Cover
Manhole covers tend to be made out of concrete or cast iron, so it’s no surprise that they can be incredibly heavy. Depending on the type and state of the manhole cover may affect how you’re able to go about lifting it, so we’ll cover off intact and damaged manhole covers.
How to Lift a Manhole Cover That’s Intact
If you want to lift the cover by hand and it’s been there for some time, the first thing you’ll want to do is remove as much of the dirt, moss and rust from around the edges as possible. You can use a screwdriver or something similar to scrape around the edges to loosen it. You can then use a screwdriver to wedge it open and a spade or similar to further lift the edge until you can safely support and lift. Strong hooks or lifting keys can also be used and are highly recommended for safety – some manhole covers will require a lifting key in the first place. Don’t forget, it’s important that you make an assessment before going ahead and attempting to manually lift the cover yourself – don’t risk personal injury.
If you’d prefer to lift the cover using a lifting system, there are a variety of different ones to choose from (including mechanical and hydraulic) depending on your requirements. The benefits to a lifting system are you don’t need manhole lifting keys, you don’t have to physically get involved and it can be a quicker process. The only downside is it’s a higher expense. If you’re unsure on which type of lifting system would be best for you, safety lifting gear can help.
How to Lift a Manhole Cover That’s Damaged
If you’re looking at lifting a damaged manhole cover, it’s important to do a proper inspection before you go ahead. We don’t recommend you attempt you remove a damaged manhole cover by hand, and that you opt for a suitable lifting system as previously mentioned. If you’d rather not tackle it yourself, you can seek the help of a drainage company who will be able to safely remove it for you.
You will also need to make sure a suitable replacement cover is sourced.
Can One Person Lift a Manhole Cover Safely?
Lifting a manhole cover alone is not recommended. Most covers weigh in the region of 90 and 150 pounds, which is far beyond safe lifting limits for a single person (55lbs). Attempting it can lead to serious injuries, including back strains or crushed fingers.
If a manhole cover must be lifted, using proper tools, mechanical aids or enlisting a second person is strongly advised to ensure safety and compliance.
Should You Check Anything Before Lifting a Manhole Cover?
Yes, several precautions should be taken before lifting a manhole cover. Check for traffic or nearby hazards, ensure proper protective gear like gloves and steel-toed boots are worn and inspect the cover for damage or corrosion.
Also, be sure to confirm the area is well-ventilated if gases could be present below. Using appropriate lifting tools and following local safety regulations is also essential to prevent accidents or injuries.
Tools and Equipment for Safe Manhole Cover Lifting
To address the challenges of lifting manhole covers, a range of specialised tools and equipment is available to make the task safer and more efficient. One of the simplest options is the manhole key. These are basic tools designed to hook into the cover’s lifting points, allowing workers to lift manually. While effective for lighter covers, they do not reduce the physical effort required for heavier ones.
For steel and cast-iron covers, magnetic lifters offer a more sophisticated solution. These tools use strong magnets to secure the cover, allowing for easy lifting and repositioning. They are particularly useful when covers need to be moved by a single person, reducing the risk of strain injuries.
Hydraulic lifters are an excellent choice for particularly heavy or difficult-to-remove covers, such as those made from concrete or tightly fitted cast iron. These lifters use hydraulic power to lift the cover with minimal physical effort, making them ideal for industrial applications.
Another versatile option is the portable cover lifter, which combines levers and wheels to make the process of lifting and moving manhole covers both simple and safe. These lifters are especially useful in environments with uneven surfaces or limited space.
Proper use of these tools is essential to ensure safety. Workers should receive training in the correct handling of lifting equipment, and all tools must be inspected regularly to ensure they remain in good working condition. Matching the right tool to the specific type of manhole cover is also crucial. For example, using a magnetic lifter on a non-metallic composite cover would be ineffective, while a hydraulic lifter might be excessive for lightweight materials.
How to Fit a New Manhole Cover
If you have a manhole that needs a new cover, as a starting point, you’re going to need to make sure you order the right size manhole cover to fill the fissure properly. Here are some useful tips which you can use as a guide when fitting a manhole cover:
- Measure the size of the clear opening – don’t measure the previous cover.
- Make sure when you remove the old cover that you remove the old frame too.
- Repair any damage to the surrounds of the manhole.
- Don’t opt for a cheap cover – it will need to be British Standard Approved for safety.
- You’ll need to fit the frame and secure it with cement under and around it, ensuring it’s level.
- You can then place the manhole cover in its correct position, being careful to lift it safely using the correct equipment.
- You can seal the edges using a joint sealer if you wish.
How to Cover a Manhole Cover
All buildings projects will require covers for manholes, for both aesthetic reasons and safety. Covered manholes blend better with their surroundings as you can use the same materials to fill in the cover as the rest of the building project flooring. This is where recessed manhole covers are useful. They’re the easiest way to ‘cover’ a manhole cover, as concrete, or whatever material you’re using, can be used to fill in the cavity on the top, creating a seamless base that blends in perfectly. Opting for recessed manhole covers still offers the convenience of easy access to the drainage system, yet they’re still strong enough to be suitable for both pedestrians and vehicles. Recessed manhole covers are the perfect solution to hide the access to the drainage system whilst still providing the necessary access for water companies. Why are manhole covers round?
How Drainfast Can Help
Once you know what type of manhole cover you need, buying replacement manhole covers is straightforward. At Drainfast, we supply a large variety of manhole covers and grates, including lifting keys, so no matter what replacement cover you need, the chances are we stock it for your building project.
All our products are British Standard Approved, and you’ll find our manhole covers are available in a variety of sizes, shapes and materials for added convenience. If you have any questions about our product range, please feel free to contact us at our head office or visit one of our UK depots.
Written by
Mark Chambers
Head of Marketing
As Head of Marketing, Mark plays an active role in running strategic projects to increase our brand profile.
