Fabricated Steel
Access Solutions
Fabricated Steel Access Solutions
EJ manufacture an extensive range of access
solutions in a variety of materials - galvanised
steel, stainless steel, aluminium, ductile iron
and composite in our world class production
facilities, certified to the ISO 9001, ISO 14001
and OHSAS 18001 management systems.
Suitable for Water, Sewer, Industrial,
Telecommunications, Power and Rail
applications, our access covers are available in
hinged or drop- in formats, with lift assistance
in accordance with manual handling
regulations. Fall protection safety grids and a
range of locking variants are also available.
Our Birr, Ireland facility accredited to ISO 9001, ISO 14001 and OHSAS 18001 management systems.
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Fabricated Steel Access Solutions
Table of Contents
Guide to Product Selection ProductDescription
3
Installation Instructions 15
Corrosion Protection 17
Network Security 17
Page
Fabricated Steel
Above Ground covers and frames
5
Flush Fit covers and frames
7
Drop in covers and frames
9
Recessed covers
10
Hinged recessed covers
11
Safety and Security accessories
13
Drawings,photographs and weights are given as an indication only.
Our policy is one of continuous product improvement, we reserve the right to modify
product specifications without prior notice.
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Fabricated Steel Access Solutions
Guide to selecting your choice of Fabricated Steel solution
From the site survey stage through to the design, installation and maintenance of your product, EJ are committed to working
with you, offering custom built access solutions that meet the highest standards in the world.
Select your choice of access cover from the options listed below by using the abbreviations (in bold) and following the column
sequence, for example Cover type, Loading, Finish, Size / Chamber opening etc.
Access Covers - Solid Top
Cover type
Loading
Finish
Size /Chamber Opening
Opening
Lift Assist
Odour
Seal
Locking Mechanisms
Above Ground-AG
15 kN-1
Solid top-S
1st dimension indicates
the cover hinge side
Hinged-A
Torsion Springs-H
Seal-J
Padlock facility 1 Padlock-V1
Flush Fit-FF
125 kN-2
Drop in Cover-TS
A x B for example:
1500 x 700mm =
150 070
250 kN-3
Compression Strut-HR
Padlock facility 2 Padlocks-V2
Gas Strut-U
Padlock facility 3 Padlocks etc-V3
M16 bolt (Socket head
capscrew)-M16
400 kN-4
(Padlock supplied by others)
A flush fit cover,125kN loading, solid top with a clear opening of 1500 x 700mm, hinged, torsion spring, odour sealed and lockable would contain
the following abbreviations:
FF 2 S 150 070 A H J V1
Access Covers - Recessed type
Cover type
Loading
Finish
Size /Chamber Opening
Depth of
recess
Recessed Drop
in Cover-TR
15 kN-1
Recessed
-R
1st dimension indicates
the cover hinge side
80 mm-R80
125 kN-2
Recessed Hinged
- RS
(stainless steel
strut)
250 kN-3
A x B for example:
600 x 600mm =
060 060
400 kN-4
Lift Assist
Odour
Seal
Locking Mechanisms
Seal-J
Padlock facility 1 Padlock-V1
100 mmR100
*48 mm-R48
*75 mm-R75
*90 mm-R90
Recessed Hinged
- LYNX
Padlock facility 2 Padlocks-V2
Compression Strut
-HR
M16 bolt (Socket head
capscrew)-M16
OTC bolt - VOTC
Gas Strut-U
(Padlock supplied by others)
A drop-in recessed cover,15kN loading, with a clear opening of 600 x 600mm, 80 mm depth of recess would contain the following abbreviations:
TR 1 R 060 060 R80
*Depth of recess applies to the recessed hinged products
Additional specifications - abbreviations can be added to the end of the product code
100 µm = 100 Micron Galvanisation
VS = Vibration Sensor (only available on Double Skin units)
140 µm= 140 Micron Galvanisation
PT = Painted
IM = Insect Mesh
AS = Anti-skid coating
AB = Alarm Bracket
EC = Epoxy Coating
AI = Alarm Installed
ME = Moat Draining Externally
MS = Motion Sensor Installed
MI = Moat Draining Internally
DS = Double Skin - secondary protection
Additional Security for Key Assets
Accredited by the Loss Preventation Certification Board (LPCB)
LPCB Security Rating 3 SR3
LPCB Security Rating 4 SR4
Please refer to our DEFENSO brochure for more information on our advanced security range of Above Ground and Flush Fit covers
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Fabricated Steel Access Solutions
Safety Grids
Item
Load bearing
Structure type
Safety blocking at 90°
No of parts
Location of Safety Grid hinge
Safety Grid-GS
300 kg-30
Jail Bar-J
Blocking-B
1
Hinged on left side - L
150 kg-15
Welded Mesh No blocking-NB
2
Hinged on right side - R
(50 x 50 mm)-M05
Walk on-W
3
Hinged on cover side - F
4
Hinged on opposite side
to cover hinge - B
A 300kg resistant, jail bar type grid, with a safety block at 90º, hinged on the opposite side to cover hinge would contain the following
abbreviations:
GS 30 J B 1 B
Secondary grid access and cut outs are also available on the safety grids, hinged or unhinged please consult us for more information.
Product selection and site risk assessment are the responsibility of the project designer. The above information serves
as a guide only, our experienced technical team are available for site visits and to make recommendations on choosing
the correct access solution. Please contact us on 057 91 23100.
Our covers and frames are hot dipped galvanised to BS EN ISO 1461 - giving a coating thickness of 70 microns, which is a
standard coating where corrosion resistance is required. Refer to page 17 for additional corrosion protection.
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Fabricated Steel Access Solutions
AG range of Above Ground covers and frames
Designed to prevent the ingress of rainwater
Hinged, torsion spring assisted cover
Locking
Padlock Facility
Place of installation
· Non-traffic areas only
· Dry, humid, corrosive environments
Material
· Hot-dip galvanised mild steel
Option :
· Stainless steel – 304 grade standard
· 316 grade optional
Hinged and
assisted cover –
for easy handling
and safety for the
operator, reducing
the lifting to less
than 25 kg.
Hand operated
safety blocking
system
Unobstructed clear opening for ease of access
Smooth visible surface
Option: tread plate – anti skid pattern
Anchoring bolt
holes
Options:
·Safety grids – see page 13 for more details
·Sealed unit
·Insect mesh
Locking options
·M16 OTC bolt
·M14 OTC bolt
·M12 CHC bolt
·1/4-turn OTCI
The torsion springs developed by EJ are calculated by our design engineers for each individual product:
· Reducing the cover lifting effort to less than 25kg
·Preventing the cover from slamming when closing
· Require limited maintenance
Refer to the table for the range of clear opening sizes available in single,double,triple and multiple
leaf variants
For advanced security options designed to prevent unauthorised access to key assets please refer to our DEFENSO brochure
outlining our Above Ground (AG) covers and frames which are accredited by the Loss Prevention Certification Board (LPCB) in the
UK, to Security Level 4
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Fabricated Steel Access Solutions
Clear opening: Select from table of dimensions below, 1st dimension indicates the cover hinge side
AG Clear opening sizes (additional dimensions available upon request)
Hinged Side
Dimensions
in mm
300
A
B
300
400
500
600
700
800
900
1000
1100
1200
1300
1400
1500
1600
1700
1800
1900
2000
2100
2200
2300
2400
2500
2600
2700
2800
2900
3000
3100
3200
3300
For internal openings less than 350 mm x 350 mm, the option inner leaf is always fitted
400
500
600
700
800
900
1000
1100
1200
1300
1400
1500
1600
1700
1800
1900
2000
1 cover
2 covers in-line hinged
2 covers end hinged
3 covers in-line hinged
Needs 1 padlock
Needs 2 padlocks
Needs 2 padlocks
Needs 2 padlocks
(2 master lids & 1 slave)
Other key features for our fabricated products include:
- increased thickness of zinc coating through galvanisation for enhanced
durability. By increasing the thickness we can double the service life of
the unit. Site specific factors which may affect the average corrosion
rate (μm per annum) can be taken in account at the design stage.
- powder coating for durability and increased resistance to corrosion.
We can offer powder coating to the C5 Industrial and C5 Marine
categories. Powder coated surfaces are more resistant to
chipping, scratching, fading, and wearing than other finishes.
- multiple leaf units
- unobstructed clear openings
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Fabricated Steel Access Solutions
FF range of Flush covers and frames
Designed for regular parking and pedestrian areas
Hinged, torsion spring assisted cover
Place of installation
· Pedestrian and Parking areas
· Landscaped / paved areas
· Dry, humid, corrosive environments
Load class
· 15 kN - 125 kN - 250 kN - 400 kN
Material
· Hot-dip galvanised mild steel
Option :
· Stainless steel – 304 grade standard
· 316 grade optional
Locking
Padlock Facility
1/4-turn OTCI
Hinged and assisted
cover – for easy
handling and safety
for the operator,
reducing the lifting to
less than 25 kg.
Opening/closing
assistance by torsion
spring for easy
handling
BS Keyways spring loaded
mechanism closes off keyway
after removal of key
Hand operated safety
blocking system
Odour Seal
Options
· Unobstructed clear opening for ease of access
· Safety grids – see page 13 for more details
· Sealed unit
Refer to the table for the range of clear opening sizes available in single,double,triple and
multiple leaf variants
For advanced security options designed to prevent unauthorised access to key assets please refer to our DEFENSO brochure
outlining our Flush Fit (FF) covers and frames which are accredited by the Loss Prevention Certification Board (LPCB) in the UK,
to Security Levels 3 and 4.
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Fabricated Steel Access Solutions
Clear opening: Select from table of dimensions below, 1st dimension indicates the cover hinge side
Dimensions
in mm
300
A
400
500
B
300
FF Clear opening sizes (additional dimensions available upon request)
400
500
600
600
750
750
900
900
1000
1200
1400
1600
1000
1800
2000
Hinged Side
1200
1400
1600
1800
2000
2200
2400
2600
1 cover
2800
2 covers in-line hinged
3000
3200
2 covers end hinged
3400
3 covers in-line hinged
3600
Needs 1 padlock
Needs 2 padlocks
Needs 2 padlocks
Needs 2 padlocks
(2 master lids & 1 slave)
Other key features for our fabricated products include:
- increased thickness of zinc coating through galvanisation for enhanced
durability. By increasing the thickness we can double the service life of
the unit. Site specific factors which may affect the average corrosion
rate (μm per annum) can be taken in account at the design stage.
- powder coating for durability and increased resistance to corrosion.
We can offer powder coating to the C5 Industrial and C5 Marine
categories. Powder coated surfaces are more resistant to
chipping, scratching, fading, and wearing than other finishes.
- multiple leaf units
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Fabricated Steel Access Solutions
TS range of Drop-in covers
Place of installation
· Pavements, Parking areas, Slow moving traffic (excluding 15kN
version)
· Landscaped / paved areas
· Dry, humid, corrosive environments
Load class
· 15 kN - 125 kN - 250 kN - 400 kN
Material
· Hot-dip galvanised mild steel
Suitable for occasional access
Un-hinged, un-assisted cover
BS keyways
Locking options
Padlock Facility
M16 bolt
Non standard openings can be catered for on trenches
including different angles on corners
Options
·Thread plates or smooth surface
· Additional anchor points
· Specific keyway shapes
· Safety grids see page 13 for more details
Wide range of clear opening sizes available
Our fabrication facility contains the most advanced technology in the world, such
as laser cutting which allows for precision parts to be designed. Customised
markings are also available to indicate the type of service or utility provider.
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Fabricated Steel Access Solutions
TR range of Recessed covers
Place of installation
· Pedestrian and Parking areas,
· Slow moving traffic (except 15kN)
· Landscaped / paved / public areas
Load class
· 15kN- 125 kN- 250 kN - 400 kN
Material
· Hot-dip galvanised mild steel
Suitable for occasional access
Depth of recess
80 mm or 100 mm
as standard
additional options
available
15kN Load Class
On large beamed multiples, one or more hinged covers with lift assist for
frequent access can be integrated into the unit
Mesh fitted in tray to provide
grip for infill material
Depth of recess
80 mm or 100 mm as standard
additional options available
Options
· Locked
· Sealed unit
125kN, 250kN, 400kN Load Class
Wide range of clear opening sizes available
in single, double, and multiple tray variants
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Fabricated Steel Access Solutions
RS range of hinged recessed covers
Hinged, with lift assist, maintenance free
Hinged and assisted
cover – for easy
handling and safety
for the operator,
reducing the lifting to
less than 25 kg.
Locking
OTC key
Options
Padlock facility
Cushioning insert
Place of Installation
· Pedestrian and Parking areas
· Landscaped / paved areas
· Dry, humid, corrosive environments
Load class
· 250 kN - 400 kN
Material
· Hot-dip galvanised mild steel
Option
· Stainless steel – 304 grade standard
· 316 grade optional
Invisible hinges for seamless integration into its area
of installation
Patented stainless
steel spring strut for
easy
closure.
Easy and safe strut
installation:
No gas leakage, greatly
extended service life,
little or no maintenance
Automatic cover
blocking in open position
Intuitive unblocking
Unobstructed clear opening
for easier access
Depth of recess 48mm, 75m or 90mm
The mechanical compression spring developed by EJ is calculated by our design
engineers for each product to meet your safety requirements:
· reduces cover lifting effort less than 25 kg
· no effort to close the cover
· easy and safe installation after filling
· very limited maintenance required
Wide range of clear opening sizes available
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Fabricated Steel Access Solutions
LYNX range of hinged recessed covers
Hinged with lift assist
Hinged and
assisted cover –
for easy handling
and safety for the
operator, reducing
the lifting to less
than 25 kg.
Locking
OTC key
Options
Padlock facility
Place of installation
· Pedestrian and Parking areas
· Landscaped / paved areas
· Dry, humid, corrosive environments
Load class
· 250 kN - 400 kN
· Hot- dip galvanised mild steel
· Mild steel gas strut (option stainless
steel)
Option
· Stainless steel – 304 grade standard
Cushioning inserts
to minimise noise
Opening/closing
assistance by gas strut
for easy handling
Option
Walk on grid
Depth of recess 48 mm, 75 mm or 90 mm
Wide range of clear opening sizes available
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Fabricated Steel Access Solutions
Safety and Security accessories
At EJ we incorporate safety practices into every process, product and service we provide - from
design and manufacture through to distribution and end use. Our highly trained and experienced
in-house product development teams will provide the optimum solutions to solve customers’
installation requirements and operational needs.
Specifications
· Resistance 150 or 300 kg
· Auto blocking at 90°
· One man operation (lifting effort less than 25 kg)
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· Lockable on request (padlock not supplied)
·Removable
· Delivered with a lifting chain for safety grids
· Assembled on a product or wall chamber
mounting option
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Fabricated Steel Access Solutions
Jail bar type grid
Mesh type grid to be fixed to the
chamber wall
Grids with secondary hatch or cut out
Allows access to equipment
without opening the grid completely.
2, 4, 6 part safety grids:
suited for pump removal
2LR (Grids hinged on adjacent sides to the Cover hinge side i.e Left and Right)
2FB (Grids hinged on parallel sides to the Cover hinge side i.e Front and Back)
used for extraction of 1 pump
4LR or 4FB Grid layout, is used for extraction of 2 pumps.
6LR or 6FB Grid layout, is used for extraction of 3 pumps.
Grid hinged on Left Side
Hinged on same side to cover hinge -Front
Safety Grid
Hinged on opposite side to cover hinge -Back
Grid hinged on Right Side
Cover Hinge Side
Safety railings
Various options on safety and fall protection railings are available in compliance with Health and Safety regulations.
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Fabricated Steel Access Solutions
Installation Instructions
Flush Fit - FF covers and frames
1. Handle the product with slings.
Check the load capacity of the slings according to the weight indicated on the product drawings.
2. Rebate:
a) Prepare a rebate corresponding to the dimensions and material shown on the product drawings.
Concrete 3000 psi (20 MPa) minimum and concrete block full solid 12MPa minimum
b) Clean the rebate surfaces.
3. Installation, levelling and shuttering:
a) Centre the product over the clear opening of the chamber. Refer to product drawings or if necessary temporarily open the hatch and
then close it after centering.
b) It is important that all anchor support points are utilised to secure the product.
Anchor bolts should not be over tightened, as this can cause frame distortion/deformation.
c) Create form work /shuttering if necessary.
d) I t is imperative that the covers are completely closed/secured while levelling the frame and during the rebate curing process.
4. Fixing:
a) Prepare the concrete seal according to manufacturer’s recommendations. Concrete 3000 psi (20 MPa minimum) A quick-setting non
shrinking mortar is recommended if normal curing time for standard mortar cannot be secured (minimum 7 days).
b) Pack up the mortar under frame and along the formwork. The frame must be fully in contact with the fixing material to ensure a
uniform distribution of the load and avoid distortions.
c) Fill the rebate unless a layer of asphalt is specified, in which case a 20 mm depth must be left unfilled.
d) C
over the filled rebate with wet canvas or tarpaulin to prevent excessive drying. Wait for complete curing of concrete.
5. Finishing
a) Remove shuttering.
b) Render the chamber wall with mortar if necessary.
c) Open the cover and clean the entire product with water if necessary.
d) Close the product.
The product is ready for use.
Flush Fit, assist lift unit
Please note these instructions are provided for general
information. The contractor installing the product is responsible
for carrying out local risk assessment and safely installing the product.
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Fabricated Steel Access Solutions
Installation Instructions
Ø22 mm holes provided for anchor bolts
Above Ground - AG covers and frames
1. Handle the product with slings.
Check the load capacity of the slings according to the weight
indicated on the product drawings.
2. Support:
a) Prepare a chamber corresponding to the dimensions and
material shown on the product drawings.
b) Clean the surfaces.
3. Installation, fixing:
a) Centre the product over the clear opening of the chamber. Refer
to product drawings and open the hatch.
b) Place anchor bolts into each of the Ø22 mm holes in the frame.
If the frame is in several pieces, each piece must be secured.
It is important that all anchor support points are utilised to secure the product (especially on long units with multiple hinge locations) Anchor bolts should not be over tightened, as this can cause frame distortion/deformation
Upstand cover, assist lift with single safety grid
4. Fixing:
a) If required, pack up the mortar under the frame. The frame must be fully in contact with the fixing material to ensure a uniform distribution of load and avoid distortion.
5. Finishing:
a) Clean the entire product with water if necessary.
b) To ensure tightness, provide a seal between the frame and the
chamber with a suitable sealant.
c) Close the product.
Upstand cover, assist lift with 2 part safety grid
The product is ready for use.
Please note these instructions are provided for general
information. The contractor installing the product is responsible
for carrying out local risk assessment and safely installing the product.
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Fabricated Steel Access Solutions
Corrosion protection
Protection by galvanisation and powder coating
In particularly extreme indoor environments such as with industrial
applications or outdoor environments such as coastal areas, where
there is:
· a high frequency of condensation
· nearly non-existent ventilation
· a highly polluted environment, with SO2 contents between 90
μg/m3 and 250 μg/m3
an additional coating such as powder coating will be required.
Galvanisation lifetime
140 μm
140
100
100
n
ba
Ur
M
150
ar
in
e
Ind
us
tria
l
200
Coating thickness in microns
By increasing the thickness of zinc coating through galvanisation,
we can double the service life of the unit.
All fabricated steel access covers by EJ are galvanised after
manufacture in accordance with BS ISO 1461.
This standard for corrosion protection is sufficient in most
environments. However, for project sites with greater exposure to
corrosion, EJ has also developed processes to effectively and
sustainably increase rust prevention.
By increasing the thickness of the zinc to 140 µm, the service life of
the device can be doubled.
140
140
100
100
100
l
Rura
100 μm
65 μm
65
65
65
65
50
0
10
20
30
40
50
60
70
80
90
years
Lifetime before 1st maintenance
The table above summarises the typical service life of the coating based on its
thickness (65 / 100 and 140 µm) and its outdoor environment (rural/ urban/ marine
and industrial).
For the most corrosive atmospheres, take advantage of our
experience and proven technologies.
Network security - protect your assets
4
+
LPCB range4
LPCB range
security
1. Protection against theft by using:
· a captive hinge
· and/or blockage by pin
+
security
You can choose from a range of security
options:
3
2. High level of security
Quarter-turn locking:
· stainless steel
· with non-standard bolt head/ opening key
configurations, not commercially available
3. Optimum security
Undetectable quarter-turn locking
· stainless steel
· with non-standard bolt head/ opening key
configurations, not commercially available
2
1
- -
undetectable
¼ turn locking
3 undetectable ¼ turn locking
with
customised
with
customisedkey
key
¼2 turn
locking
with
¼ turn
locking
with
customised
keykey
customised
Captive
hinge
hinge
1 Captive
or/and
spring
blocking
or/and
blocking
pin pin
1 - Theft
1 - Theft
2 - High
security
2 - High
security
LPS
1175:
Issue
77
LPS
1175:
Issue
Cert
No.
1187a
Cert
No.
1187a
3 - Optimum
security
3 - Optimum
security
4. Anti-terrorism security
· Our DEFENSO range is LPCB certified (issue 7) by a third party the BRE laboratory in Great Britain.
Available on the AG and FF ranges, used on numerous infrastructure networks throughout the world.
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- Anti-terroristsecurity
security
4 -4Anti-terrorist
Fabricated Steel Access Solutions
Global expertise. Local understanding.
EJ designs, manufactures and distributes access solutions for water, sewer, drainage, telecommunications and utility networks
worldwide. For over 125 years, we have fostered strong relationships around the world and we excel at serving our customers by
leveraging our global and local strengths.
Castings by EJ are made from recycled materials, with ferrous scrap metals as the primary component. Every day we recycle
hundreds of tonnes of post consumer material into useful products. Our solutions have a very long service life and typically require
little or no maintenance. You can be assured that products that bear our name are endorsed by independent certification bodies who
work to the same high standards and values as we do.
We also specialise in major civil engineering projects including airports, ports and carriageways. Our innovative range of
products are specified on numerous prestigious projects throughout Ireland and the UK such as:
Dublin & Shannon Airports
Port of Felixstowe
Edinburgh Airport
Dublin Port Energy for Waste Projects · countrywide
Belfast International Airport
M6 Birmingham
Manchester Airport Edinburgh Trams
LUAS Light Rail Tram System Dublin
M50 Motorway upgrade
Heathrow Airport
N52 Mullingar to Tyrrellspass
Corrib Natural Gas Terminal
M6 Galway to Athlone Motorway
For more information on our range of innovative access solutions
please call us on 057 91 23100 - to speak to one of our Sales Engineers, or visit ejco.com
Featuring a comprehensive product database with
advanced search and browsing capabilities
- register on ejco.com for access to:
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Specification information
Customisable project lists
Literature
Videos
Installation instructions
Scan this QR code to visit
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set up your user account.
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Fabricated Steel Access Solutions
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+1 800 874 4100
EMEA
Europe, Middle East
and Africa
+33 344 08 28 00
Asia-Pacific
+61 73216 5000
Registered
marks
Ireland
Roscrea Road
Birr
Co Offaly
T: 057 91 23100
F: 057 91 20954
ireland.sales@ejco.com
CAVANAGH®
NORINCO®
TELECOM®
SELFLEVEL®
ERMATIC®
CHILDSAFETY®
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DEFENSO®
NORGUSS®
CABLECOM®
NORLONG®
MAXIMO®
AQUERA®
Fabricated Steel Access
Solutions 2015