High strength, light weight, abrasion resistant, UV stabilized, corrosion and abrasion resistant, anti slip/ anti skid, zero scrap value, less expandable fibre reinforced plastic manhole cover with frame and method of manufacturing thereof, characterised in that the bottom mould and top mould as shown in figure. 1,2 and 3, containing base support (1) detachably associated with base mould (2) in desired shape, a release agent (3) layer is provided to prevent adhesion of gelcoat layer (4) to mould surface for demoulding the final product, a non porous, resin rich gelcoat layer (4) is applied alongwith resin, additives, hardeners, pigments and fillers, and a reinforcement layer alongwith resin and hardeners is applied on gelcoat layer which is known as gelcoat reinforcement layer (5) which is being provided to prevent product from toxic gasses/liquids, a first resin impregnated reinforcement layer (6) is applied on reinforced gelcoat layer which is extended horizontally and vertically in a such a way that it can wrap all the layers, multiple reinforcement layers (7), impregnated with resin and hardener to provide for desired strength are applied on the first reinforcement layer, a polyconcrete (8) mixture made up of resin, hardeners, additives and fillers is poured on the multiple reinforcement layers to form a core which imparts rigidity, strength to the product, the entire assembly is then subjected to mechanical vibrations through vibrating means and the resin mixed with hardeners is poured on polyconcrete core (9) to fill up the air voids that remains even after vibration, the complete assembly is then wrapped up with the extended first reinforcement layer to cover the entire system, resin putty paste mixed with hardeners (10) is then applied on the wrapped up reinforcement layer to provide better bonding between the top and bottom parts of the product an abrasion resistant, anti - skid / anti - slip, UV stabilised decorative, and flexible top mould (figure 4) layer, having chamfered edges is provided to avoid chipping.
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