The Role of FRP in Reducing Embodied Carbon in Infrastructure

Embodied carbon—the total greenhouse gas emissions associated with a product’s lifecycle from production to disposal—is a critical metric for sustainable infrastructure. Fiber Reinforced Plastic FRP manhole covers are gaining attention for their ability to reduce embodied carbon compared to traditional materials like cast iron. This blog examines how FRP contributes to low-carbon infrastructure across its lifecycle.

Production: The production phase is a major driver of embodied carbon. Cast iron manhole covers require mining, smelting, and molding, processes that consume vast amounts of energy and emit 1.8-2.2 tons of CO2 per ton of iron produced. FRP, made from fiberglass and resin, has a lower energy footprint, typically emitting 20-40% less CO2 per unit. Advances in FRP manufacturing, such as using recycled fibers or bio-based resins, further reduce embodied carbon by minimizing reliance on virgin materials. For cities installing thousands of covers, these savings add up significantly.

Transportation: FRP’s lightweight nature—up to 70% lighter than cast iron—reduces embodied carbon during transportation. Heavier cast iron covers require more fuel for shipping, increasing emissions, especially for long-distance transport. For example, transporting 1,000 FRP covers might save thousands of liters of fuel compared to cast iron, directly lowering embodied carbon.

Installation: Installing cast iron covers often requires heavy machinery due to their weight, adding fuel-related emissions to the embodied carbon total. Because FRP covers are lighter, they may frequently be erected by hand or with less complicated equipment, which saves energy. This difference is particularly impactful in dense urban areas, where installation logistics are complex and machinery use is emissions-intensive.

Service Life: FRP’s durability significantly reduces embodied carbon over time. Cast iron covers frequently need to be replaced within ten to fifteen years due to their propensity to corrode and shatter.With each replacement cycle, additional emissions are produced, transported, and installed. Because FRP covers are resistant to corrosion and environmental stressors, they require little maintenance and can last for 20 to 30 years or more. Because there will be fewer replacements due to this longer lifespan, the embodied carbon from repetitive production and logistics will be reduced.

End-of-Life: At the end of their life, FRP covers can be recycled into new composites, a process with lower energy demands than cast iron recycling, which involves energy-intensive melting. By designing FRP covers for circularity, manufacturers reduce the embodied carbon of disposal, aligning with sustainable infrastructure goals. In contrast, discarded cast iron covers often contribute to landfill emissions if not recycled.

By reducing embodied carbon across production, transportation, installation, service life, and disposal, FRP manhole covers offer a compelling solution for low-carbon infrastructure. As cities prioritize materials with minimal environmental impact, FRP’s ability to cut emissions while maintaining performance makes it a cornerstone of sustainable urban development. Adopting FRP can help municipalities build resilient, decarbonized infrastructure for the future.