In the transition to greener infrastructure, all parts of the project count – from design to delivery.  FM Conway has been at the forefront of this for decades, and its latest successful low emissions scheme demonstrates its commitment in action.  In partnership with National Highways – and our strategic supply chain – working on junctions 15 and 16 of the M4, FM Conway has set a new low-carbon benchmark on the strategic road network. 

By Matt Tallon, sustainability director at FM Conway

The core aim of the project was to resurface the carriageway between junctions 15 and 16 on the M4.  Supported by National Highways’ Low Carbon Demonstrator Fund (LCDF), an initiative to rapidly scale low carbon materials, methods and technologies, the aspiration was not only to complete this work but to produce as few emissions as possible in the process. This meant making sustainable choices at every stage while reducing the need for ongoing maintenance and repairs.  Together with our supply chain, we achieved all of those objectives. 

Saving time and improving quality, side-by-side

130,000 vehicles use the M4 each day, so delivering projects on this part of the strategic network both on time and with minimal disruption is a key priority.  To do this, an innovative echelon paving technique was used, allowing two strips of asphalt to be laid at the same time, bonding together seamlessly.  The result?  Fewer shifts were needed to complete the work, there were fewer road closures and there was less disruption to road users. 

As a business, we are always looking to the future for technology which can set the standard for road quality.  On the M4, this took the shape of laser profiling, which automatically detects lumps and bumps in a surface to be corrected when asphalt is laid – a surefire way to reduce the need for further repairs, improving durability and vehicle efficiency for road users.

Ultimately, carbon savings don’t end when a road is built.  In fact, the biggest opportunity sits in how long that road lasts.  High quality, durable roads need fewer repairs, which means lower construction activity and less emissions over their lifetime.  Put simply, building better roads upfront reduces the carbon cost of maintaining them for decades.

Integration leads to accomplishment

It wasn’t just the methods used that made the scheme sustainable – through the support of the LCDF and our specialist supply chain, FM Conway brought together the use of JCB’s Hydrogen 3CX backhoe loader, refuelled at a nearby Ringway depot, with Sany’s electric roller and planer. Ensuring that fossil-fuel reliance was reduced beyond just the works, the zero-emission equipment was transported to and from the site by a fully-electric Volvo lorry. This was a team effort which helped turn a bold idea into a reality.

The materials matter

11,000 tonnes of asphalt were laid in the six-week project.  Waste materials from other roads operated by National Highways, including the M11, A34 and A3, were re-used in this project.  60 per cent recycled asphalt product (RAP) was used in the base and binder, while mixes containing 30 per cent RAP were laid on the surface course. Alongside recycled content, the asphalt manufacturing was powered by biogas, reducing overall project emissions by a third, a strategic choice to strengthen the road laid and reduce emissions.

Results that speak for themselves 

Delivering 630 tonnes of CO2e savings (50 per cent) when compared with a standard design – all while delivering the scheme at speed – is proof that bringing expertise together to create a more sustainable strategic network works.

Decarbonisation can go hand-in-hand with delivering long-term performance on our road network, but to do this, it must be considered at each stage of a project. The right partners, machinery, and materials chosen, supported by clients willing to challenge established methods, all play a part in delivering infrastructure which is both sustainable and long-lasting.

About FM Conway 

FM Conway is a leading infrastructure services company. We inspect, design, build, enhance and maintain essential infrastructure services for the public sector and community.

With over 60 years’ experience, we pride ourselves on being an industry leader and innovator, especially in recycling and reuse. We have a network of asphalt and aggregate recycling manufacturing plants serving London and the wider regions throughout the UK, as well as a Thames-side wharf and our own research and development laboratory. 

We recycle 98% of highway arisings, including kerbs, paving and concrete and we have the ability to produce asphalt with a high recycled content and a low carbon footprint. 

We are British Standards Institute (BSI) PAS 2080:2023 certified for management and reduction of whole-life carbon in infrastructure and the built environment.  We are a member of the British Safety Council, the Civil Engineering Contractors’ Association, and the Quarry Products Association, as well as being BSI registered for environmental and quality management. 

We are multi-award winning in our approach to road safety and were the first company in the UK to have achieved British Standard ISO 39001, which provides a framework to help organisations reduce the incidence and adverse effects of road traffic accidents.

Please visit www.fmconway.co.uk

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