The Melton Mowbray Distributor Road represents a nationally significant milestone in sustainable carriageway construction. Delivered between 2024 and 2026 the scheme demonstrates how Holcim UK collaborated with Leicestershire County Council (LCC), Galliford Try and AECOM to optimise pavement design, reduce embodied carbon and maximise material circularity on a major highways project.
The project is recognised as the first scheme in the UK to be designed and constructed using Foamix Cold Recycled Bound Material (CRBM) in the base course, while also remaining fully compliant with Specification for Highway Works Clause 948. This project establishes a benchmark for the adoption of low-carbon pavement technologies at scale.
Early engagement and specification development
Early contractor involvement was fundamental to the project’s success. From the outset in 2024 Holcim worked closely with LCC, AECOM and Galliford Try to identify opportunities to reduce embodied and operational carbon across the surfacing works.
Through collaborative specification development Foamix, Holcim’s foamed bitumen Cold Recycled Bound Material, was introduced as a replacement for traditional warm mix asphalt in the base course. The design team ensured the pavement met the performance intent of SHW Clause 948, and was measured against the new CC202 standards. This provided technical assurance and risk mitigation for the contracting authority.
This structured and transparent partnership reflects Holcim’s experience of working in accordance with ISO 44001 collaborative business relationship principles, enabling innovation without compromising delivery certainty.
Pavement design and material innovation
Foamix is a cold-laid asphalt CRBM manufactured at ambient temperatures using foamed bitumen technology and containing approximately 90% recycled aggregate. On the Melton Mowbray scheme approximately 35,000 tonnes of Foamix were laid in the base course and circa 26,000 tonnes of conventional Holcims Foamix were installed within the binder and surface courses.
The ambient production process significantly reduces energy demand and limits binder ageing when compared with warm and hot mix asphalts. Performance compliance was validated through laboratory testing, site trials and ongoing quality assurance during construction.
The project demonstrates that Holcim’s Foamix can be successfully specified as a structural base course solution on major infrastructure schemes while maintaining full compliance with national standards.
Carbon reduction and environmental performance
The introduction of Foamix delivered substantial carbon savings across the scheme. The substitution of warm mix asphalt in the base course achieved an overall carbon reduction of approximately 60% reducing total embodied carbon from 1,700,000 kgCO₂e to 672,174 kgCO₂e.
These savings were achieved through:
• Ambient temperature production
• High recycled material content
• Reduced transport distances
• On-site manufacturing efficiencies
In addition the use of high recycled content materials prevented the extraction of approximately 32,000 tonnes of virgin aggregate, directly reducing demand on primary quarry resources and supporting LCC’s sustainability and net-zero ambitions
Circular Economy and hazardous materials management
Circular economy principles were embedded at the core of delivery. Approximately 30,000–35,000 tonnes of Leicestershire’s existing road planings were recycled back into the new distributor road through Foamix.
A key technical challenge involved managing approximately 4,500 tonnes of hazardous planings that would typically require disposal to licensed landfill. Following technical assessment and mix design optimisation these materials were safely encapsulated within the Foamix base layer. This approach avoided landfill disposal, generated significant cost savings in hazardous waste management and removed an estimated 200 HGV movements from the local road network.
By reusing site-derived materials at scale the project demonstrated how environmental responsibility and commercial efficiency can be delivered simultaneously.
Fleet, logistics and on-site production
Further carbon and operational efficiencies were achieved through logistics innovation. Holcim deployed an on-site Sitebatch facility to manufacture all Foamix material directly within the scheme boundary.
On-site batching eliminated the need for repeated HGV movements to and from off-site asphalt plants, resulting in a saving of approximately 43,000–45,000 vehicle miles. This reduced fuel consumption, transport emissions and congestion while also improving safety by limiting heavy vehicle interactions on the local network.
The approach enhanced programme resilience, ensured full production control and minimised disruption to the surrounding community.
Delivery performance and collaborative success
The project was delivered to the agreed programme and within budget, achieving maximum carbon savings alongside strong health and safety performance. The works were completed with zero reportable accidents, zero complaints and positive feedback from both the client and the local community.
Holcim’s collaborative approach, technical expertise and commitment to innovation enabled the successful integration of new national guidance with practical construction delivery setting a precedent for future CRBM adoption.
Social value and community legacy
Beyond technical delivery, Holcim implemented a comprehensive programme of social value initiatives designed to provide lasting community benefit. These included financial contributions to local community groups such as the Melton Round Table Father Christmas Rally and Melton Mowbray Rotary Club, resurfacing works at John Fearnley College, delivery of a student speed networking event through the Leicestershire Education Business Company, donation of materials to surface a local Scout campsite and surfacing works for the local Air Ambulance car park.
These initiatives were delivered alongside the core works, ensuring the project generated tangible and enduring benefits for communities directly affected by construction activity.
Benchmarking sustainable highways construction
The Melton Mowbray Distributor Road establishes a new benchmark for sustainable highway construction in the UK. As the first scheme designed and delivered with a Foamix CRBM base course under National Highways SHW Clause 948, it provides a live reference for authorities seeking to reduce embodied carbon, maximise material reuse and safely manage hazardous arisings without compromising structural performance.
By combining early contractor involvement, on-site production, cold recycling technology and high recycled content materials, Holcim UK has demonstrated that major infrastructure can be delivered with measurable environmental, economic and social benefits.
The project provides a clear, scalable pathway for the wider adoption of Cold Recycled Bound Materials across the highways sector.
