A 5,330m² stretch of carriageway in Cheshire has been resurfaced with a material system that cuts embodied carbon by 54%. The scheme uses recycled ash, biochar and a plant-based binder, storing carbon within the road structure itself.
The project won the Steve Berry Innovation Award at the Highways Awards and was shortlisted for the Highways UK Excellence Awards. It represents an approach to sustainable highways maintenance that reduces “cradle-to-laid” carbon emissions by more than half while increasing material reuse.
Recycling and bio-based binders in action
The resurfacing was delivered by Colas in partnership with Cheshire West and Chester Council, Breedon and Multipave Infrastructure on Corkscrew Lane. It combines proven low-carbon road technologies previously used in France and adapts them to UK conditions.
The redesigned binder course uses Valorcol cold recycled bound material (CRBM) made entirely from recycled or waste materials, including reclaimed asphalt pavement (RAP), incinerator bottom ash aggregate (IBAA) and biochar. Biochar is a carbon-rich material that stores biogenic carbon, locking emissions into the road.
Production and installation of the CRBM occur at ambient temperature, reducing energy use. Bitumen emulsion used comes from Colas’ Warrington plant.
The surface course features Colas’ Vegeroad bio-binder, a mix that includes plant-based lignin. This lowers fossil bitumen content and increases carbon storage within the road layer.
Cutting carbon and material waste
The project shows a 54.1% reduction in embodied carbon compared with traditional hot-laid surfacing, based on industry-recognised lifecycle assessments and additional independent analysis.
Virgin material use fell by 55%, supporting resource preservation and circular economy principles.
Meeting UK highways needs with sustainable materials
The innovations demonstrated are compatible with UK road construction practices and regulations, including NRSWA and the Traffic Management Act. They maintain expected performance, durability and resilience on local roads while lowering environmental impact.
Driving collaboration and carbon goals
Oliver Thomas of Colas said: “This project demonstrates how innovation can help transform the way we maintain and renew our road networks. Working closely with Cheshire West and Chester Council, Breedon and Multipave Infrastructure, we have successfully adapted technologies already used in France for the UK market, creating a practical pathway towards more sustainable road maintenance.”
Karen Shore, Cheshire West and Chester Council’s Cabinet Member for Transport and Highways, said: “As a Council, we are committed to finding innovative ways to maintain and improve our roads while reducing our impact on the environment. This project demonstrates how partnership working and new technologies can help us make significant progress towards our carbon reduction goals without compromising the quality and resilience of our highway network.”
She added: “The results achieved on Corkscrew Lane show the potential for sustainable solutions to play an increasingly important role in the future of highways maintenance.”
