Cold Bitumen Innovation Cuts Carbon on National Highways Scheme

A National Highways project has successfully used a low-carbon asphalt alternative, marking a significant step forward in sustainable road construction.

Roadways supplied and installed a cold bitumen emulsion-based asphalt as a direct replacement for traditional materials during works on the A26 at Beddingham and the A259 at Winchelsea. By classifying the product as a like-for-like substitute under Clause 948 of the Specification for Highways Works, the company avoided the need for lengthy trial periods typically required for new materials.

This approach is believed to be a first on the strategic road network, potentially paving the way for faster adoption of lower-carbon construction methods.

The material itself is produced using 100% recycled aggregate, removing the need for virgin resources in the layer where it was applied. Roadways handled all aspects of the project, acting as contractor, manufacturer, and installer. Production took place at its East Sussex recycling facility, where road planings removed during the works were processed and reused.

Early collaboration played a key role in the project’s success. A design query raised by Roadways prompted discussions with National Highways and scheme designers, ultimately confirming the material could replace AC20 binder within existing specifications.

The environmental benefits were significant. By eliminating the need for high-temperature production and installation, the project reduced emissions considerably. Approximately 1,300 tonnes of material were used, delivering an estimated carbon saving of between 23 and 25 tonnes of CO₂. Additional savings of around 2.4 tonnes were achieved through efficient logistics, including back-haul operations that reduced empty vehicle journeys.