How do I replace trapdoor access in decking, over pool filter pipework?

[di9]

I can't for the life of me find out what this type of access hatch is called so I can see about replacing it.

What is it called and where can I get a replacement?

Pics:

Description:

It's outside a small property close to the sea. It houses the gubbins for a small pool. It's metal, extremely heavy, has no hinges, rests loosely in a metal frame, and has a handle (of sorts) at each end. (Removable wooden floor sections cover it when closed, so it should take the weight of people/garden furniture on top.)

As you can see, it's all rusted and corroded so badly that I think it's only a matter of time before there's severe personal injury.

Ideally I want to replace the entire "hatch" with something much lighter - at the moment it takes 2 people to lift it. What are my options and who supplies these things? Is it custom or off-the-shelf?

Also, do those "handles" have a name? I want to replace them as soon as possible because they look like they're about to snap. But what with? Would nylon rope do temporarily?

Approx dimensions: "Hatch" 144cm x 103cm; "Handles" 14cm long w threads about 10cm long that are spaced about 12cm from each other.


Thank you very much.

 

[HERTS P&D]

It was probably made on site.

Andy

 

[freddiemercurystwin]

How about solid top GRP sheet? eg https://www.industrialmetal.co.uk/2...z8JC6i81Cl9KWvutOVfvJUMFimejHGrBoC3x0QAvD_BwE

 

[foxhole]

Low profile trench cover may do it with modification , or get blacksmith to make up replacement in aluminium (lighter and won’t rust ), won’t be cheap .

 

[Harry Bloomfield]

It's custom-made for the job.... Replace it with - Aluminium chequer plate, bolted to a steel, galvanised angle frame.

 

[Tigercubrider]

It would help if you described the materials.
I am assuming a frame made off angled steel and a steel tread plate cover?

You could make a replacement frame out of aluminium square tube if the space below is available?
The joints are ABS.
Then a lid of aluminium plate or construct it with timber to match the existing surround

 

[di9]

Thank you, everyone! All that info is extremely helpful! Re what the existing materials are, I'm too much of a novice to say, other than it is very heavy, metal, and it rusts. I'll look into GRP sheet - never knew it existed!

But from your comments it sounds like it was made to measure. I don't have the tools or skills to build something like that from metal, so I'll either have to get someone in or order a made to measure part. For the latter, I've found a place in France(!) that makes something that to me looks similar, in aluminium for around 700 euros (around £600). This is the part. (No affiliation; it's the only place I've found so far by googling.)

Is that silly money or reasonable?

Price aside, is it a suitable replacement?

Edit: This property is in Spain, if I didn't mention it before.

 

[Harry Bloomfield]

Is that silly money or reasonable?

Seems expensive to me. Ten years ago, I bought a piece of alloy chequer plate, around twice the size of the piece you probably need, it cost me £20. It was to make a ramp, to enable a mobility scooter to be ridden into our hut.

Price aside, is it a suitable replacement?

It says 'custom', so should be OK, and comes with the surround, which will require some fitting.

 

[di9]

@Harry Bloomfield Vey helpful, thanks!

One more thought. Does the existing metal frame look reusable? It has rust, but it looks less corroded to me than the top plate. So I'm wondering if getting a plate cut to size and having it welded on top of the existing frame is another option, even though going this route wouldn't reduce the overall weight as much as I'd like.

In that scenario, I guess if that top plate is aluminium it would also need extra bracing underneath? But maybe aluminium won't weld to the current frame? Gah, too much I don't know. Maybe what I should do is go away and learn enough about welding and metalwork.

 

[cdbe]

Looks perfectly repairable to me - take it to a metal fabrication place and ask them to clean it up (shot blast it or similar) assess the condition - (it looks over engineered for it's function) repair the broken welds, and give it a coat of paint.

 

[martygturner]

get it refurbished add a couple of hinges and a pair of gas struts.

 

[di9]

Looks perfectly repairable to me - take it to a metal fabrication place and ask them to clean it up (shot blast it or similar) assess the condition - (it looks over engineered for it's function) repair the broken welds, and give it a coat of paint.

Brilliant! This adds to my options. Thanks!

get it refurbished add a couple of hinges and a pair of gas struts.

Great idea I hadn't thought about! If I go this route, any pointers on the sort of struts to go for/avoid?

 

[JohnD]

It's in decking. Normally a carpenter could make a matching trapdoor out of decking materials. Your recessed handles are unusual, but fold down ring pulls are common.

You say you are near the sea, so outdoor steelwork will quickly rust. I use stainless steel outdoors for this reason.

Derusting and using metal protective paint will help. You must not have any gaps or chips in the coating and it should be done before assembly to cover hidden parts.

If there is any chlorine escaping from the pool, it will corrode anything.

A boatbuilder or maintenance yard could provide a hatch.

 

[JohnD]

Boat hatch

 

[Harry Bloomfield]

Looks perfectly repairable to me - take it to a metal fabrication place and ask them to clean it up (shot blast it or similar) assess the condition - (it looks over engineered for it's function) repair the broken welds, and give it a coat of paint.

It looks odd, to my eyes in the first photo - the chequer plate looks very thin, and strangely, quite thin and wrinkled along the edge. Were it me, I would remove the chequer plate, from the angle iron frame, have the frame cleaned up, painted, then add some alloy chequer plate on top, by bolting the two together, with stainless steel, countersunk head bolts.

Welding the alloy to steel, will not work..