FM Conway and National Highways have delivered a first-of-its-kind low carbon scheme on the M4, combining hydrogen and electric plant to resurface the carriageway between Junctions 15 and 16, including the first use of JCB’s hydrogen 3CX backhoe loader on the strategic road network

 

The scheme was about showing how low carbon materials, innovative paving techniques and low emissions machinery can be combined to accelerate the transition to greener infrastructure. It delivered a carbon saving of 50% (630 tonnes of CO2e) versus the standard design.

 

The M4 is one of the busiest motorways in the UK, carrying over 130,000 vehicles every day, making it the ideal test case for demonstrating how more sustainable road construction and maintenance can be achieved.

 

Showcasing the power of supply chain partnerships and collaboration, this scheme brought together JCB’s hydrogen 3CX backhoe loader for the first time on the UK strategic road network, accompanied by Sany’s electric planer and 4.5 tonne roller – which were all transported on Volvo’s fully electric 42 tonne lorry. The 11,000 tonne scheme was delivered over six weeks using low carbon material.

 

The teams coordinated planning for electric charging and hydrogen refuelling infrastructure alongside support from the National Highways team and its Low Carbon Demonstrator Fund.

 

This collective effort paves the way for sustainable delivery across the strategic network, said Andy Weymouth, framework delivery manager at FM Conway: “Delivering this scheme on time and to such a high standard was only possible through genuine collaboration with our partners – we all played a vital role. It took belief in a shared goal and a healthy dose of commitment to integrate the use of these new technologies effectively.

 

 

“Angela Halliwell, Head of Carbon and Air Quality at National Highways, said: “We’re committed to cutting carbon from road maintenance and are proud to support the acceleration of new low‑carbon technologies, helping bold projects like this become a reality.

 

 

The integration of hydrogen and electric machinery, right through to the road laying method, the way equipment was moved, and the materials used, means emissions were cut at every stage of the job.

 

 

The JCB Hydrogen 3CX backhoe loader is the only machine of its kind run by a hydrogen internal combustion engine. Powered by Ryze Fuels, with refuelling set up at Ringway’s Stanton Depot for this scheme, the loader is the lowest carbon option available for this machinery and delivers the same performance as traditional diesel models. In addition, FM Conway used Sany’s electric roller and planer to complete the surfacing work. The trio of vehicles were transported to and from site on a Volvo electric low loader powered by Volvo’s fully electric 42 tonne lorry.

 

 

To lay the asphalt, FM Conway used a technique called echelon paving, where both lanes of a carriageway are laid simultaneously to remove weak joints between lanes and improve road quality. It is a faster method of working, requiring fewer shifts to complete and reducing road closure periods, re-routing and disruption.

 

A further technique used was laser profiling, which helped create a smoother surface by detecting surface irregularities that could then be corrected during the laying process. By creating more durable surfaces which develop fewer cracks, these two methods reduce the need for future repairs.

 

 

The asphalt mix was engineered to maximise recycled content. Recycled asphalt product (RAP) was taken from other National Highways operated roads, including the M11, A34 and A3. Mixes containing 60% RAP were laid in the base and binder courses, while mixes containing 30% RAP were laid in the surface course.