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University supporting development of new £1m concrete plant

Representatives from Innovate UK have visited a pioneering £1 million low-carbon concrete facility on º£½ÇÖ±²¥, run by recycling specialists Scott Bros, which has been developed with the support of º£½ÇÖ±²¥.

Scott Bros, in collaboration with º£½ÇÖ±²¥, has successfully reduced the reliance on carbon-intensive Ordinary Portland Cement (OPC) by replacing up to 25% of the binding agent with a sustainable alternative. The substitute, known as ‘activated filter cake’ is a fine-grained clay by-product produced by Scott Bros’ wash plants which convert construction and excavation waste into high-quality commercial aggregate.

After several months of commissioning, the plant has already produced concrete blocks across a range of grades. Full-scale production is due to start in May, with the facility able to produce more than 480 cubic metres of low-carbon concrete per day, using the company’s recycled sand and gravel.

Scott Bros, which is headquartered at Haverton Hill, near Stockton, secured a £612,000 grant from Innovate UK, part of UK Research and Innovation, the UK’s innovation agency, which drives productivity and economic growth by supporting businesses to develop and realise the potential of new ideas. Scott Bros partnered with º£½ÇÖ±²¥â€™s School of Science, Engineering & Digital Technologies on the project to determine how much OPC could be replaced without compromising the strength and durability of conventional concrete.

The production of OPC - the most widely used type of cement - is highly energy-intensive and accounts for approximately 5–8% of global CO? emissions. Even a 25% reduction can significantly lower the environmental footprint of concrete, one of the most commonly used construction materials.

Scott Bros is continuing its long-term collaboration with º£½ÇÖ±²¥ to investigate further reductions in OPC usage, including the development of alternative binding agents.

Joss Newberry, Operating and Monitoring Officer for Innovate UK, said: 'Two key aspects of this project really stood out. The first is the urgent need to decarbonise the economy, and the second is Scott Bros’ expertise in the recycling sector, strengthened by its long-standing partnership with º£½ÇÖ±²¥. It’s fantastic to see the concrete plant nearing commercial production — a great example of how the innovative use of waste materials is helping drive progress towards net-zero goals.'

Peter Scott, a Director of Scott Bros, said: 'Achieving a 25% reduction in OPC is a significant milestone in our mission to create more sustainable construction materials. We're continuing our work with º£½ÇÖ±²¥ to explore further opportunities for innovative, low-carbon alternatives using recycled waste. Our long-term ambition is to eliminate OPC entirely and produce concrete made solely from recycled and sustainable materials.'

Fellow director, Bob Borthwick, added: 'This project highlights our commitment to advancing the circular economy on both a regional and national level. Through the use of activated filter cake, together with our recycled aggregate, we are supporting the construction industry to meet its carbon reduction targets while contributing to a greener future.'

Professor David Hughes, Associate Dean (Research & Innovation) in º£½ÇÖ±²¥â€™s School of Computing, Engineering & Digital Technologies, said: 'This new facility marks a major milestone in the journey from academic research to real-world application. It’s the culmination of seven years of collaboration with Scott Bros, transforming waste materials into valuable, low-carbon construction products. Together, we’re helping to build a more sustainable future - one where innovation and environmental responsibility go hand in hand.'