Unite™ & Unite™ Evolution

Ductile iron D400 CD534 access covers

Uite logo

Simply the best D400 access cover range available in the market. Full of patented design features that combine together to give Unite the longest life and therefore lowest whole life cost of any D400 access cover. Designed and manufactured to exceed BS EN124 and Highways England’s Design Manual for Roads and bridges (DMRB) specification CD 534 which recently replaced HA104/09.

The engineering team at Wrekin have a deep understanding of pavement and highway ironwork performance. Using the very latest tools and software, the Unite™ range of manhole covers and gully gratings has been engineered for extremely long life.

Key to Unite’s longevity is minimising seat wear between covers/gratings and frames. By successfully challenging manufacturing conventions, the range has the stiffest cover/grating structure in its class and on top of this, seating which is less vulnerable to any movement caused by cover/grating flexing that might take place. The structure is patent protected.

By incorporating patented features Wrekin has also designed Unite™ to work sympathetically with bedding mortars thereby reducing stresses on the frame foundation – identified by WRC as a major cause of manhole cover failure.

To increase surface contact with bedding materials the underside of the Unite™ frame features an engineered tread pattern and to inhibit crack initiation all contours of the Unite frame, where it engages with the bedding materials, are fully rounded – both patented features unique to this product range.

Wrekin have designed Unite™ to work perfectly with UniPak™ bedding system, the leading frame foundation system. Comprising polyester resin mortar, packing plates, adjustment wedges and sharing design principles from the Unite™ frame, the patented system bonds to form a homogenous, highly durable foundation structure.

Engineered for very long life:

  • In service on highways for over 15 years
  • Over 500,000 installations with zero reported failures
  • Patented cover / grating designs substantially reduce seat wear
  • Patented frame features are sympathetic to bedding materials.
  • Exceeds BS EN 124-2:2015
  • Complies with DMRB CD534 and Series 500
  • Kitemarked by BSI
  • 100% recyclable product

Service life and the impact on society:

Typically, ironwork replacement takes around 3 hours.* Studies show the 2000 users per hour of A-roads are delayed by an average of 4mins in roadworks** This loss of earnings / productivity equates to over £2200 per hour. The saving to society of not having a 3-hour long unnecessary manhole replacement is at least £6600 and cuts the associated noise, dust and waste.

*Based on independent analysis commissioned by a major water utility. **Statistics collated from Department for Transport & The National Traffic Survey 2014

Unite™ Evolution

 

Wrekin’s Unite™ Evolution is full of patented design features which combine together to give Unite™ the longest life and therefore lowest whole life cost of any D400 access cover on the market. Unite™ exceeds both BS EN 124:2015 and DMRB CD534 requirements.

The Unite™ Evolution features an internal sealing face that allows any user to add a class 2 or class 3 seal plate (As defined by WRc). The same seal plate unit can be drilled to facilitate ‘Low Leak’ performance.

Unite™ Evolution is a development of Wrekin’s highly successful original Unite™ range, with the new, innovative product evolving from its predecessor to include patented design features that combine to give the longest life, and therefore lowest whole life cost, of any D400 access cover on the market. Using the latest design tools and software, Unite™ Evolution has been engineered for an extremely long life. By successfully challenging manufacturing conventions, Wrekin has created Unite Evolution to be the most durable cover in its class by limiting cover flexing and therefore seating wear. 

By incorporating patented features Wrekin has also designed Unite™ Evolution to work sympathetically with bedding mortars thereby reducing stresses on the frame foundation – identified by WRC as a major cause of manhole cover failure. 

To further increase asset life, resistance to wear has been enhanced by providing a large interface between covers and frame 

To improve traffic load distribution on the foundation materials, Unite™ Evolution features a new, more sophisticated tread configuration. This patented feature was developed in response to site observations, which found mortar had failed to adhere to the ironwork. The tread feature and accompanying mortar holes have proven significantly more effective in interlocking with the bedding material than the flat underside flange faces of other products. 

Unite™ Evolution also incorporates additional features to solve specific issues facing Local Councils. It is essentially four products in one as it has a built in internal accessory receiver for retrofit seal plates and it is also the first manhole cover on the market that has a removable ID bolt.

Internal accessory receiver:

Unite™ Evolution now incorporates an internal skirt with a sealing face to mate with different specifications of seal plate, depending on the application requirements.

 

Improved mortar ‘gripper’ system:

Unite’s patented ‘tread’ feature was developed in response to site observations, which often found mortar had failed to adhere to the ironwork.

The tread feature and accompanying mortar holes have proven significantly more effective in interlocking with the bedding material than the flat underside flange faces of other products.

To further improve traffic load distribution on the foundation materials, Unite™ Evolution features a new, more sophisticated tread configuration.

 

Improved cover seating area:

To further increase asset life, resistance to wear has been increased by providing a larger interface between covers and frame. Unite™ Evolution provides a 50% increase seating material and wear surface compared with the original 2001 design.

Locking bolt provision:

In order to provide controlled access, manhole covers and gully gratings can be supplied with robust factory-fitted screw fasteners.
A specifically formed recess is provided for this purpose.

 

 

Replaceable Asset Identifier:

The most noticeable update from the original Unitedesign is the provision for a user-replaceable identification found on the UniteEvolution. It is primarily used to notify the asset owner if the cover has a NoLeak/LowLeak accessory fitted but could also be used to brand covers in low quantities.

Identifier bolts can be changed on site using simple tools and can be branded to virtually any design.

The bolts could be used as a marker for:

  • Ownership, such as ‘TfL’
  • Application, such as ‘Standard’, ‘FW’, ‘SW’, ‘Low Leak’
  • Status, such as ‘Operational’, ‘Danger – Do Not Enter’

The identifier bolt is protected from trafficking by a ductile iron ring cast into the cover that sits proud of the surface of the bolt. It is also designed so it won’t spin in its seating.

Endless Possibilities:

The identifier bolt has the potential to incorporate RFID (Radio-frequency identification) technology to enable NFC

(Near-field communication) asset management or sensors to record for example traffic, chamber flow

data etc.

 

 

Unite™ Evolution Seal Plate Configurations: 

 

Key features:

D400 For use in a Group 4 Class D400 carriageway environment
Fully compliant with BS EN 124:2015
kitemark Third party certified by BSI
Complies with DMRB (Design Manual for Road & Bridges, CD534)
Complies with MCHW (Manual for Contract Highway Works, Series 500)
HA104-09 Complies with Highways England specification HA 104/09
support symbol Cover support geometry reduces movement relative to the frame
framegrip symbol Under frame grip – engages with bedding mortar reducing lateral shift
enlarged flange Enlarged frame corners help to dissipate the load
ant-flex beam Antiflex cover – reduces cover wear
non-rock Non rock – three point suspension for non rock stability
keyway Safety keyway – ensures key’s secure in keyway when lifting
ductile iron Manufactured from strong and highly durable ductile iron
GritBlocker™ anti-blockage keyway elastomeric insert pre-installed
indexed covers Indexed covers ensure correct fitting
Mechanical lifting points
Patented mortar stress-arresting frame edge
Provides mechanical anchorage between mortar and frame
Customer or application specific retrofittable ID badge provision

Unite™ Evolution Sizes and Availability:

Wrekin product code Clear opening size (mm) Frame depth (mm) Over frame size (mm)
DMT0D6/6060/KUEO 600 x 600 150 820 x 820

Sealing Plate:

Wrekin
product code
Description Weight
(kg)
Size
(mm)
DMT0D6/6060/KUELTW LowLeak sealing plate with elastomer
gasket seal and drilled hole
25 600 x 600

Available options:
SW or FW integrally badged (other badging available on request).
Ventilation holes, locked covers, safety grilles, sealing plate, ID bolt, Anti-slip Coating (60+ PSRV).

Unite™ Sizes and availability

Wrekin product code Clear opening size (mm) Frame depth (mm) Over frame size (mm)
DMT0D4/6060/KU 600 x 600 100 810 x 810
DMT0D6/6060/KU 600 x 600 150 810 x 810
DMT0D4/6767/KU 675 x 675 100 890 x 890
DMT0D6/6767/KU 675 x 675 150 890 x 890
DMT0D6/1267/KU 1200 x 675 150 1480 x 915
DMT0D6/1867/KU 1830 x 675 150 2075 x 920
DMT0D6/6060/KUULL 600 x 600 150 875 x 875
DMT0D6/6767/KUULL 675 x 675 150 933 x 933

Available options:
SW or FW integrally badged (other badging available on request).
Ventilation holes, locked covers, safety grilles, flood and odour control plate, Anti-slip Coating (60+ PSRV).

Download PDF data sheets

Unite Range

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Flood and odour control plate

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Flood and odour control plate