When choosing a cover for your pump station, the two most common options are composite and cast iron. Each with its own advantages proves selecting the right one to be a tough decision as factors like environment, load requirements, safety, and long-term durability must be considered. This guide breaks down the key differences to help you make an informed choice.
What Are Composite and Cast-Iron Covers?
Cast iron covers have long been the industry standard for sewer and stormwater infrastructure. Made from heavy-duty metal, these covers are known for their strength and ability to withstand high loads.
Composite covers are made from fiber-reinforced plastic materials (such as glass-reinforced polyester). This modern alternative is engineered for strength while being lightweight and corrosion-resistant, making composite access covers a smart choice for many newer installations.
Key Differences Between our Composite and Cast-Iron Covers
| Feature | Composite Covers | Cast-Iron Covers |
| Weight | Lightweight – easy to handle without machinery | Heavy – often requires mechanical lifting |
| Corrosion Resistance | Excellent – ideal for corrosive or coastal environments | Poor – prone to rust in harsh or wet conditions |
| Durability | Can handle up to 510kgs (class A load rating), can become brittle over time | Can handle up to 8,000kgs (class D load rating), can rust over time |
| Safety | Slip-resistant surface and non-conductive | Can become slippery when wet; conductive |
| Access | Easier to lift for maintenance crews | Heavier to lift, requires more time and OH&S risks |
| Cost | Higher upfront cost but lower maintenance over time | Lower upfront cost but higher maintenance over time |
When to Use Composite Covers
Composite covers are ideal for:
- Sites where higher class ratings aren’t needed
- Corrosive environments
- High pedestrian areas needing anti-slip surfaces
- Sites with frequent access needs, where manual lifting is a factor
- Installations prioritising worker safety and lower long-term costs
Whether you’re upgrading a pump station or installing new infrastructure, composite access covers offer an innovative solution with strong safety and performance benefits.
When to Use Cast-Iron Covers
Cast iron covers are ideal for:
- Roads and driveways with frequent or heavy vehicle traffic (e.g., trucks, forklifts)
- Industrial areas with strict Class D load rating requirements
- Sites where tamper resistance is important (heavier covers deter unauthorised access)
- Non-corrosive, inland environments where rusting is less of a concern
- Projects where upfront costs need to be minimised and lifting equipment is readily available
A cast iron sewer cover is often the go-to for applications requiring maximum strength and security, especially in trafficable areas.
While cast iron access covers are still widely used in traditional infrastructure, the popularity of composite access covers is growing rapidly, especially in stormwater and wastewater infrastructure. Their ease of use, safety benefits, and resistance to corrosion make them especially well-suited to both applications.
Need Help Choosing the Right Cover?
The Global Water team can help you select the best cover based on your project needs, environment, and load class requirements. We supply a full range of composite and cast-iron access covers to suit all standard sizes and applications.
Get in touch with our team or check out our pump station accessories today.
Tags: Wastewater, Maintenance, Stormwater, Pump station covers, Composite covers, Cast iron, Corrosion resistance
