Wrong specifications don’t just delay projects. They create liability, drive up costs, and put crews at risk. For procurement officers and contractors, the right cover protects infrastructure and reduces long-term maintenance.

Why Procurement Errors Cost Projects Time and Money

A cover with the wrong load rating, incompatible frame, or missing certifications may pass initial inspection and still fail within months. Catching mistakes at the specification stage is always cheaper than after installation.

Mistake #1 – Specifying the Wrong Load Rating

Understanding Traffic Classification

AASHTO M306 governs U.S. load ratings, requiring a 50,000-pound proof load for H-25 traffic. H-20 suits standard roads; H-25 is required for highways, industrial zones, and heavy freight corridors.

How to Match Rating to Application

Assess the installation environment and require documented test data, not just a product label. CAP composite manhole covers meet H-25 ratings, show zero permanent deformation after AASHTO M306 testing, and withstand loads exceeding 100,000 pounds.

Mistake #2 – Overlooking Required Certifications

Federal and Load Rating Requirements

Federally funded projects must comply with the Buy America Act (BABA), which requires that a product be manufactured in the USA and that at least 55% of the component’s costs come from US sources. Meeting that threshold is only part of the compliance picture; a product can be domestically manufactured and still carry an unverified load rating. Listing “H-25” without requiring AASHTO M306 test data can allow untested products to slip through.

Documentation to Request from Suppliers

Ask suppliers for proof of load test results, DOT approval letters, BABA certification, and installation guides before any product is specified. These documents confirm that a cover meets both performance and compliance requirements, not just on paper, but in verified testing. CAP holds the first unrestricted “within roadway” DOT approval for composite covers in the U.S. Visit justcapthat.com to learn more.

Mistake #3 – Choosing the Wrong Material for the Environment

Coastal and Corrosive Environments

Bacteria in sewer systems generate hydrogen sulfide gas, which converts biologically into sulfuric acid, contributing to an estimated $276 billion in annual U.S. corrosion losses. CAP composite covers resist hydrogen sulfide, moisture, salt, and chemicals with no decline in strength over time.

High-Traffic vs. Pedestrian Areas

In high-traffic zones, deflection under load is a safety concern even without visible deformation. CAP’s ribbed thermoset construction limits deflection – while holding 50,000 pounds – to 1/8 to 1/4 inch. And, when loads are released, CAPs have zero permanent deformation, easily passing the AASHTO Proof Load requirements.

Mistake #4 – Ignoring Frame Compatibility

New Cover Installation vs. Raising Covers

A manhole cover and frame must be ordered and specified as a matched set. That compatibility requirement doesn’t end at installation. When roads are repaved, the surrounding surface rises, and raising the cover to match requires hardware that works with the original frame. Traditional raises can add $5,000–$10,000 per manhole and require up to 24 hours of concrete curing. The HALO™ riser ring, compatible exclusively with CAP frames and covers, installs in minutes for $300–$500, with no excavation needed.

Mistake #5 – Selecting Suppliers Without Verified Track Records

Questions to Ask Your Supplier

Ask about domestic manufacturing, DOT approvals, lead times, and BABA compliance. CAP covers are molded in Texas, installed in over 1,000 cities across 48 states, and ship within 2–3 weeks. CAP won the ACE Award in 2020 and was nominated again in 2023. Avoid suppliers who cite ratings without AASHTO M306 test data or offer minimal bolt thread engagement. CAP bolts feature ten full threads, approximately three times more than some imports.

Procurement Checklist for Infrastructure Projects

• Load rating confirmed and AASHTO M306-tested
• DOT approvals and BABA certification documented
• Material suited for the exposure environment
• Cover and frame specified as a compatible assembly
• Future repaving costs are factored into the total budget
• Supplier has real-world references

Request a Specification Review

Explore the full range of composite manhole covers for sale or connect with CAP’s team at justcapthat.com or (844) 344-CAP1. Learn how to buy the correct manhole cover!

The descriptions in this article regarding iron manhole covers may not represent the performance of all traditional materials, manufacturers, processes, treatments, installations, system types, geographic locations, practices, or other conditions.