Lightweight molded covers and plates

A method for forming a cover for an underground structure or a plate for covering a hole, the method comprises the steps of:

• providing a mold cavity configured in a predefined shape to form the cover for the underground structure or the plate for covering the hole;
• introducing a first portion of a polymer mixture into the mold cavity so that the first portion of the polymer mixture is proximate a bottom surface of the mold cavity;
• placing an edge reinforcement layer along at least one side of the mold cavity such that a first portion of the edge reinforcement layer is within the first portion of the polymer mixture and proximate the bottom surface of the mold cavity;
• placing a top reinforcement layer within the first portion of the polymer mixture and proximate the bottom surface of the mold cavity, wherein the first portion of the edge reinforcement layer and at least a portion of the top reinforcement layer overlap;
• placing a core in the mold cavity proximate the top reinforcement layer;
• placing a bottom reinforcement layer proximate the core;
• introducing a second portion of the polymer mixture into the mold cavity;
• and
• folding a second portion of the edge reinforcement layer such that the second portion of the edge reinforcement layer and at least a portion of the bottom reinforcement layer overlap with a portion of the second portion of the polymer mixture arranged therebetween.