M20 Junction 5 – Delivering Significant CO2 Savings with Low-carbon Steel

thyssenkrupp Materials Trading UK, part of thyssenkrupp Materials Services, partnered with Davro Steel to supply carbon-reduced steel products for vehicle restraint systems for the M20 Junction 5 improvement scheme in Kent. With sustainability high on the agenda, Highways England sought innovative approaches to reduce embodied carbon across the project. thyssenkrupp Trading UK supplied low-carbon steel to Davro, who processed and delivered the material to Hill & Smith, the barrier components manufacturer, setting a new benchmark for sustainable infrastructure projects.

The challenge

This high-profile infrastructure project came with clear sustainability objectives. Highways England brief focused on reducing the carbon footprint associated with materials supply and construction. Specific challenges included:

·         Sourcing alternative materials without compromising on performance or compliance

·         Maintaining manufacturing quality and durability with unfamiliar feedstock

·         Aligning the supply schedule with site logistics while introducing a new product

·         Demonstrating measurable environmental benefits to stakeholders

The solution

Low-Carbon Steel, Proven Performance

Around 50% of the VRS components were manufactured from bluemint ® recycled steel, supplied by thyssenkrupp Materials Trading UK, directly from its own steel mill in Duisburg, Germany – thyssenkrupp Steel Europe, bluemint® recycled steel offers a 64% reduction in CO2 compared to traditional blast furnace manufactured steel – a process significantly cleaner than traditional blast furnace production. Crucially, this carbon-reduced steel met the same exacting standards as conventional alternatives.

Managing Director at Davro Steel: ”Through this strong collaboration, we’ve successfully supported the supply of thyssenkrupp Steel Europe’s bluemint® CO₂-reduced steel for a prestigious UK Highways Agency project — marking a major step forward in delivering more sustainable infrastructure solutions. This achievement highlights the power of partnership and innovation in driving real progress toward a lower-carbon future. Together, we’re helping to shape an exciting new era for the industry — one where performance and sustainability go hand in hand.”

Seamless Supply, Same Standards

The components were manufactured using standard processes, hot-dip galvanised for long-term durability, and delivered in line with the programme – proving the approach is not only viable but scalable.

Outcome and Results

The M20 Junction 5 scheme delivered a tangible demonstration of how sustainability and infrastructure safety can work hand in hand. By introducing low-carbon steel without altering the system’s form, function, or installation methods, this proved that environmental benefits don’t have to come at the expense of performance or programme.

The project resulted in a verified carbon saving of 30,785 kg of CO₂, equating to:

·         The annual electricity use of six UK homes

·         The carbon absorption of 509 trees over 10 years

·         Taking seven petrol cars or 27 EVs off the road for a full year

·         Preventing the burning of over 34,000 pounds of coal

These outcomes represent more than impressive statistics – they reflect a scalable approach to carbon reduction within core infrastructure. Crucially, the switch to low-carbon steel did not require any changes to installation practice, proving the solution can be readily deployed on future schemes.