One of two international composite manufacturing sites for EJ – located in Co Offaly – produces a highly innovative, Irish-developed range of access covers using the very latest fibre-reinforced polymer composite materials, exceeding the latest European standards.

The past five years have seen the only Irish based manufacturer of composite covers go from strength to strength with notable industry awards such as the Impact Award 2018 presented by University of Limerick, and the short listing of the EJ composite project in the top three submissions for a national Knowledge Transfer of Ireland (KTI) innovation award 2018.

Innovation at Birr Composites

The result of an extensive research programme to devise how best to manufacture composite access covers using best-in-class materials and processes led to the development of the industry’s first independently certified range of composite access products.

This research was taken from the laboratory and scaled up into an innovative high-end manufacturing process in Birr, Co Offaly. Once a concept was developed which met the requirements of EN124:2015 (European product performance standard), the process had to be designed to meet the volume requirements of the customers.

'Our composite capabilities give a new dimension to our product catalogue, allowing us to create new solutions for an industry that is becoming increasingly focused on improving ergonomics, developing smart city infrastructure and environmental awareness.' Dr Vincent Cooper, product manager, composites and plastics 

Market success across Europe

One example of a recent market success has been achieving specification with a major European telecom provider. They have selected EJ as the manufacturing partner to help them transition from heavyweight concrete access covers to the lighter weight composite.

An 8kg cover now replaces the traditional concrete cover weighing 80kg. Through further collaboration a 100mm deep frame was designed to improve the client’s finished installation in paved areas.

EJ produces a highly innovative, Irish-developed range of access covers using the very latest fibre-reinforced polymer composite materials

Environment and sustainability 

The eco-design of the composite cover minimises any negative impact to the environment with a low energy consumption in a low temperature manufacturing process, and a reduced product weight which contributes to a low transportation impact. Environmental considerations are increasingly a factor in the approval process of access solutions for global service providers. 

Available in a range of colours to blend in with the surrounding area

No more so than on a Hyperscale Datacentre, located in Co Meath, with the selection of the EJ IDS ELITE and accompanying NEXUS structural chambers – manufactured from recycled material and fully recyclable, for use over their duct chambers.

NEXUS structural chambers and the IDS cover 

Evolving designs

Additional success for the EJ composites came about by evolving existing designs.  

Tailoring design to solve client’s issues

The SVELTO PLUS which offers additional features such as locking and sealing against water ingress, over the original SVELTO range, came about over a three-year development process with representatives of a water utility company in Belgium.

The client requirement was for a high quality, full composite solution that was EN124:2015 B125 compliant. It selected EJ because of its global reputation as experts in access cover design and manufacture.  

Multiple site visits were carried out by our technical engineers to understand the specific market requirements and by incorporating feedback from the client and their sales and technical teams, as well as the relevant construction companies, ensured the best possible solution was developed and manufactured to suits their needs.

A visit to the world class production facility in Birr allowed the stakeholders better understand the production process and meet the team behind the innovative design.

Composite covers are here to stay

In recent years, the arrival of composite access covers to the market has delivered new advantages and a new level of choice for project managers of utilities and municipalities, engineers, specifiers and owners. Given the potential for such a variety of products, it is important that stringent standards are in place.

For the first time, Part 5 of the revised European product standard EN 124:2015 for gully tops and manhole tops for vehicular and pedestrian areas now sets down specific requirements for access products made from composite material.

As industry leaders, EJ commissioned their own research and testing to demonstrate their commitment to the standard and to ensure all requirements are met.

In addition, EJ composite products are independently tested and accredited by the NSAI (National Standards Authority of Ireland) and carry this certification mark and give clients peace of mind that the products they approve meet their expectation.

To find out more on how you can achieve long-term value and future proof your networks with innovative, compliant access solutions in all material - ductile iron, steel and composite, across all critical infrastructure networks  contact caroline.obrien@ejco.com to organise Engineers Ireland accredited CPD Lunch and Learn seminar.