Heidelberg Materials UK has completed resurfacing works at the entrance to the Eurotunnel service tunnel in Folkestone, Kent, using a low-carbon asphalt solution designed to reduce emissions, improve durability and speed up construction delivery.
The project was delivered in collaboration with Eurotunnel Services Limited, with Heidelberg Materials supplying its Tufflex asphalt combined with CarbonLock bio-binder, a CleanAir additive and the company’s Era 140 warm mix asphalt process.
According to Heidelberg Materials UK, the alternative surfacing specification reduced the project’s carbon footprint by at least 25% compared with the original SMA specification, based on April 2026 calculations.
Low-carbon asphalt used on Eurotunnel infrastructure project
The resurfacing works covered approximately 1,600m² at the entrance to the service tunnel and emergency response vehicle garages, using around 140 tonnes of asphalt. Existing surfacing materials were removed and recovered for reuse as part of the works.
The asphalt was produced at Heidelberg Materials’ Allington plant using its Era 140 warm mix asphalt process, which allows production temperatures up to 40°C lower than conventional hot mix asphalt.
The company said the lower production temperature reduces fuel consumption and can cut associated CO₂ emissions from production by up to 15%, while also improving site working conditions and enabling faster completion of works.
Phil Greenin, Regional Manager – Contracting at Heidelberg Materials UK, said: “Sustainability is a key commitment for Eurotunnel Services Limited, so it was open to working together to find the lowest carbon solution for this project.
“It is the first time that Tufflex with CarbonLock has been used at a major infrastructure facility and was also the first time our asphalt and contracting teams worked together with Eurotunnel Services Limited in a collaborative partnership.”
Bio-binder and air quality additives included in asphalt specification
The Tufflex asphalt specification incorporated CarbonLock binder containing biogenic materials designed to absorb and store CO₂ during their lifecycle, with the carbon retained within the asphalt even after recycling.
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The binder also included Heidelberg Materials’ CleanAir additive, which the company said can reduce the release of certain gases and particulates by up to 40%.
According to the contractor, the additive was particularly suited to use within tunnel environments and low-emission areas due to its impact on air quality and odour reduction.
Construction works completed under operational tunnel constraints
The resurfacing programme was scheduled during quieter maintenance periods to minimise disruption, while maintaining emergency access to the service tunnel at all times.
The project also required the use of walking floor HGVs instead of standard tipping vehicles due to safe working height restrictions linked to adjacent tunnel electricity infrastructure.
Campbell Main, Technical Lead, Civils at Eurotunnel Services Limited, said: “It has been great to work alongside Heidelberg Materials to achieve a significant step forward in sustainable construction.
“A flexible approach and a collaborative team ethic from all parties culminated in a competitively priced carbon reducing alternative to traditional surfacing materials and the safe and sustainable delivery of this milestone project.”
