Type 1 IBAA performed exactly like primary aggregate on the A1331 Link Road Project, delivering top-tier CBR and compaction test results while proving that we can hit
low-carbon targets without compromising on build quality or the site programme.
Building low-carbon infrastructure with Reborn Aggregates
Project Overview
The A1331 Elmstead Market Bypass demonstrates how recovered materials can play a role in delivering circularity to the UK infrastructure. In collaboration with National Highways and Octavius Infrastructure, Blue Phoenix supplied 43,500 tonnes of Reborn Aggregates Type 1 IBAA for use as a road sub-base material for this major road project in Essex. By replacing primary aggregates with a certified recycled alternative, the project reduced its carbon footprint by more than 42%, saving 158,228 kg of CO2 while maintaining full technical compliance.
The project shows that high-performance infrastructure can be delivered using materials recovered from existing resources, reducing reliance on virgin extraction while meeting the demanding requirements of road construction.
52,200 t
primary resources saved
158,228 kg
CO2 saved while maintaining 100% performance
43,500 t
of Reborn Aggregates recovered from IBA used as the road sub-base
The vision
The A1331 Elmstead Market Bypass is a collaboration between National Highways, Octavius Infrastructure and Blue Phoenix to support future growth in the Tendring Colchester Borders Garden Community. Connecting the A120 and A133, the new link road will improve connectivity, support the delivery of up to 7,750 new homes, and provide the infrastructure needed for future residential, business and leisure development. Alongside delivering essential transport infrastructure, the project team wanted to embed low-carbon construction practices by incorporating secondary aggregates while ensuing the material met the required performance standards.
The opportunity
Delivering major infrastructure projects requires significant volumes of construction materials, traditionally relying on primary aggregates extracted from natural resources. As the A1331 Link Road was developed, the project team looked for opportunities to incorporate lower-carbon aggregates while maintaining high performance and technical requirements expected from a major highway project. For National Highway the important factor was to identify a material solution that could support the project’s construction needs, and contribute towards their net-zero ambitions and circular economy commitments.
The solution
Blue Phoenix provided 43,500 tonnes of Reborn Aggregates Type 1 IBAA for the A1331 Link Road project, providing a cost-effective, lower-carbon alternative to primary aggregates for use in road sub-base applications. Produced from incinerator bottom ash (IBA) processed at our Tilbury facility, Reborn Aggregates are created through advanced separation and refining technologies that recover valuable metals and mineral fractions from Energy-from-Waste residues. The refined mineral fraction is transformed into certified IBA Aggregates, quality-tested to meet the requirements of major infrastructure applications. This enables recovered materials to be used as a reliable construction resource, supporting projects that need balance performance, cost, and carbon reduction.
Benefits of building with Reborn Aggregates
The A1331 Elmstead Market Bypass demonstrates that Reborn Aggregates is a cost-effective, low-carbon alternative to traditional aggregates, supporting lower-carbon infrastructure while maintaining the technical standards required for major construction projects.
Cirular economy
42% CO2 saved
by choosing Reborn Aggregates
Transport efficiency
458 fewer
29-tonne lorry movements
Material efficiency
52,200 tonnes
less primary material required
Reborn Aggregates: A proven material for UK infrastructure
Reborn Aggregates is an extremely cost-effective material compared to primary aggregates and is regularly tested to ensure our products meet the requirements outlined in the Specification for Highway Works (SHW) and relevant European standards (EN 13242, 13285, 13043 and 12620). The result is a material that delivers the performance required for infrastructure projects while giving recovered resources a new purpose. The road carries the same traffic. The road bears the same weight, the sub-base performs just as reliably. The difference is what happens beneath the surface; materials are recovered, and returned to the construction cycle instead of relying only on newly extracted resources.
Download our case study
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Case study_A1331 Elmstead Market Bypass_Blue Phoenix
Discover more case studies in the UK
We can provide you with the right solution for every project, ensuring the safe and reliable use of recovered materials in construction. Our materials are trusted across the UK for their proven performance, quality and compliance with the highest environmental and regulatory standards. Explore our UK applications and case studies below or contact us for specific examples tailored to your requirements.
New Industrial Units, Central Park, Avonmouth, Bristol
Construction of two new industrial units with access roads, parking and pathways.
New Housing Development, Parsonage Gardens, Leigh
The development is around the corner from its name sake, Parsonage Retail Park and has close proximity to a number of picturesque parks and green spaces including Pennington Flash Country Park and Eatock Lodge Nature Reserve.
Swinton Greenway Walking and Cycling Routes
Swinton Greenway will provide an entirely traffic-free route between Swinton and Monton. The scheme will provide an attractive, safe and direct route linking existing key locations such as primary schools, high schools and a college.
New Production Facility, St Helens
This project involves the construction of a brand new sustainable glass making Pilot Plant facility in St Helens.
New Housing Development, The Greenways, Goole
An 800 dwellings greenfield housing development on Rawcliffe Road, Goole. Just off junction 36 of the M62 offering 2-, 3- & 4-bedroom homes.
Four Bay Agricultural Grain Storage Facility, Queen Elizabeth Dock, Hull
Located by the east gate entrance, this 6,600m2 project is for a new four bay gain store with a holding capacity of 40,386 tonnes.
Beverley Road Cycle Route Improvement Scheme, Hull
A £1.1 million 5km dedicated cycleway along Beverley Road, Hull from Dunswell Roundabout to Ferensway. Creating a safer cycling environment.
Connect with our experts in the UK
Our team in the UK is ready to support you with deep industry knowledge and innovative solutions. Whether you’re seeking technical guidance, partnership opportunities, or more information about our operations, our experts are here to help.