
Potholes - More Than a Surface Issue white paper The UK spends billions tackling potholes each year. Our research shows many form not from the surface itself, but from failing ironwork surrounds. Download our whitepaper to uncover the root causes and solutions. Download the whitepaper The hidden problem Potholes are usually blamed on weather and traffic, but the evidence tells a different story. The WRc Street Ironwork Report surveyed 220 manhole covers and found that 44% had failed due to break-up of the paved surround. In other words, almost half of the failures were linked directly to the materials and workmanship around ironwork. The ALARM survey adds to the picture, warning that “Opening a road to create a trench can reduce its structural life by up to 30%.” Every time ironwork is repaired or replaced, the road weakens — and the risk of pothole formation increases. When you combine these two findings, it’s clear that poor ironwork installation is one of the most overlooked contributors to the UK’s pothole epidemic. Why ironwork matters When ironwork isn’t specified and installed correctly, the surround deteriorates long before the rest of the road. Poor bedding materials, inadequate chamber top preparation and substandard installation practices all create weak points. These weak points quickly turn into cracks, depressions and, ultimately, potholes. This cycle of failure means repeated repairs, wasted budgets and ongoing disruption for road users. The problem isn’t that potholes are inevitable, it’s that we’re not addressing the root cause. Download the whitepaper A system approach to the solution Addressing surface deterioration around ironwork starts with the installation process below the road surface. Treating ironwork installation as a coordinated system can help manage issues associated with movement around frames and covers. This includes: Selecting ironwork that is manufactured in accordance with relevant standards and suited to the road environment Using bedding mortars appropriate for traffic loading conditions Preparing chamber tops prior to installation to support correct frame seating Supporting consistent installation practices across site teams We're taking practical steps to support this system approach. We are actively delivering training to contractors, giving them the skills and confidence to install ironwork properly. We also offer CPD training on the common causes of ironwork failures and the solutions. You can register for this training below. Download the whitepaper Register for training WHITE PAPER Potholes - More than a surface issue Our More Than a Surface Issue whitepaper digs deeper into the link between failing ironwork and potholes. It shares key data, explains the financial and environmental costs of repeated repairs, and sets out practical recommendations for contractors, specifiers and local authorities. If you want to understand the real cause of potholes, and what can be done to prevent them, this report is essential reading. It doesn't have to be this way Every 16seconds a pothole is filled. at a total cost of £143.5 million. 2million potholes repaired in 23/24 totalling 60,000 tonnes of CO2 emissions produced by repairing potholes in 23/24. 30kg of CO2 emitted to repair a pothole each time an access cover is cut out to repair or replace. 30% reduction in structural life Insights from local authorities ◤ Industry analysis ◤ Efficient solutions Potholes across the UK’s road and highway network are a real problem. In fact, road incidents caused by pothole related damage in June 2023 were at their worst for five years, according to the AA Pothole Tracker. But did you know ironwork specification and selection can affect and even increase the likelihood of a pothole forming? Potholes will continue to be a concern in the coming colder months due to the harsher weather conditions putting additional stress on asphalt surfaces. Our updated report explores; Some of the ways in which potholes are caused Identifies links to ironwork (both gully grates and manhole covers) What features of ironwork can increase the likelihood of pothole formation The changing road landscape with increased bus lanes and cycle routes How local authorities and industry bodies are tackling the issue, and Suggests solutions you should be looking for when specifying ironwork. Download the whitepaper Combined insight from Brighton & Hove City Council Derby City Council LCRIG Gaist Wrekin Solutions Unite Manhole Covers The Unite range of manhole covers incorporates features used within applications subject to traffic loading conditions and installation requirements. Unite D400 Gully Grates Our premium Unite D400 gully grate combines new technology with proven features to deliver a super long-life and the lowest whole-life cost of any D400 gully grate. Highway Manhole Covers The Highway range includes a wide selection of shapes, sizes and configuration options, including HaloHinge covers, which incorporate a hinged design for lifting during operation. Highway Gully Grates The Highway range offers our most extensive variety of gully grates, including three flange, four flange and V gully grates. Multigrate 250kN The temporary replacement for stolen or broken gully gratings that's simple, rapid and cost-effective to install. H2GO™ Kerb Unit H₂GO is a combined kerb and drainage unit intended for installation with a H2GO gully chute connector. Designed for linear drainage applications in Group 3 locations. H2GO™ Gully Chute Connector The H₂GO gully chute connector is used below a grating or kerb-type gully unit and incorporates a primary catchment chamber with a spigot outlet for onward pipe connection. UniPak® UniPak is a BBA HAPAS approved rapid-set bedding mortar for ironwork installations. It is used in applications where bedding performance forms part of chamber construction and installation. Related content Share this page

Potholes - More Than a Surface Issue white paper

The UK spends billions tackling potholes each year. Our research shows many form not from the surface itself, but from failing ironwork surrounds. Download our whitepaper to uncover the root causes and solutions.

Download the whitepaper

The hidden problem

Potholes are usually blamed on weather and traffic, but the evidence tells a different story. The WRc Street Ironwork Report surveyed 220 manhole covers and found that 44% had failed due to break-up of the paved surround. In other words, almost half of the failures were linked directly to the materials and workmanship around ironwork.

The ALARM survey adds to the picture, warning that “Opening a road to create a trench can reduce its structural life by up to 30%.” Every time ironwork is repaired or replaced, the road weakens — and the risk of pothole formation increases. When you combine these two findings, it’s clear that poor ironwork installation is one of the most overlooked contributors to the UK’s pothole epidemic.

Why ironwork matters

When ironwork isn’t specified and installed correctly, the surround deteriorates long before the rest of the road. Poor bedding materials, inadequate chamber top preparation and substandard installation practices all create weak points. These weak points quickly turn into cracks, depressions and, ultimately, potholes.

This cycle of failure means repeated repairs, wasted budgets and ongoing disruption for road users. The problem isn’t that potholes are inevitable, it’s that we’re not addressing the root cause.

Download the whitepaper

A man using a compactor to complete the installation of a Wrekin Unite manhole cover

A system approach to the solution

Addressing surface deterioration around ironwork starts with the installation process below the road surface. Treating ironwork installation as a coordinated system can help manage issues associated with movement around frames and covers. This includes:

Selecting ironwork that is manufactured in accordance with relevant standards and suited to the road environment
Using bedding mortars appropriate for traffic loading conditions
Preparing chamber tops prior to installation to support correct frame seating
Supporting consistent installation practices across site teams

We're taking practical steps to support this system approach. We are actively delivering training to contractors, giving them the skills and confidence to install ironwork properly. We also offer CPD training on the common causes of ironwork failures and the solutions. You can register for this training below.

Download the whitepaper Register for training

WHITE PAPER

Potholes - More than a surface issue

Our More Than a Surface Issue whitepaper digs deeper into the link between failing ironwork and potholes. It shares key data, explains the financial and environmental costs of repeated repairs, and sets out practical recommendations for contractors, specifiers and local authorities.

If you want to understand the real cause of potholes, and what can be done to prevent them, this report is essential reading.

It doesn't have to be this way

: Every 16seconds a pothole is filled.
at a total cost of £143.5 million.: 2million potholes repaired in 23/24
totalling 60,000 tonnes of CO2 emissions produced by repairing potholes in 23/24.: 30kg of CO2 emitted to repair a pothole
each time an access cover is cut out to repair or replace.: 30% reduction in structural life

Insights from local authorities ◤ Industry analysis ◤ Efficient solutions

Potholes across the UK’s road and highway network are a real problem. In fact, road incidents caused by pothole related damage in June 2023 were at their worst for five years, according to the AA Pothole Tracker.

But did you know ironwork specification and selection can affect and even increase the likelihood of a pothole forming?

Potholes will continue to be a concern in the coming colder months due to the harsher weather conditions putting additional stress on asphalt surfaces.

Our updated report explores;