SUSTAINABILITY
THE LOW-DOWN ON LOW-CARBON
The construction and manufacturing industries are at a critical juncture when it comes to addressing environmental impact, as BMJ finds out.
W
ith growing urgency around tackling climate change, the construction industry must adopt innovative approaches
to reduce carbon emissions, enhance product performance, and deliver sustainable solutions. According to David Manley, head of sustainability at Forterra , the company is committed to not only meeting these challenges but also setting a benchmark for sustainable practices within the sector.
Planet, product, people He says: “Our sustainability efforts are driven by the framework “Planet, Product, People”, ensuring that environmental, social, and governance (ESG) goals are integral to our decision-making processes. Through this framework, we are reducing CO2 emissions, reducing packaging waste, improving workforce diversity, and creating building products that support sustainable construction.
“The foundation of our sustainability strategy is a set of bold, science-based targets designed to reduce our carbon emissions by 32% by 2030. We are taking significant steps to reduce energy consumption, transition to renewable energy, and work with our suppliers to align our carbon reduction goals, positioning Forterra as an industry leader in sustainable building products.”
Desford transformation Forterra’s investment in the redevelopment of the Desford factory is, Manley says, a significant example of how the company is incorporating sustainability into its operations. Through a £95 million investment, it integrated cutting-edge technologies such as advanced kilns, improved thermal efficiency, and solar panel installations. “These innovations will reduce our carbon emissions by 25% per brick and allow us to produce 180 million bricks annually, helping to meet the growing demand for sustainable building materials,” he explains.
One of the most carbon-intensive products
as a substitute for pure natural gas in the kilns. This, Manley says, was done without altering the performance or aesthetic properties of the bricks. “We specifically examined how hydrogen, a reducing agent, could affect the colour and consistency of our bricks, with particular attention paid to the Desford red bricks. We found that the hydrogen blend had no negative impact on these critical aspects of product quality.”
He adds that a major advantage of these trials is that the company was able to conduct them using existing kiln equipment, which is designed to last 25 to 40 years. This approach avoids the significant carbon footprint that would result from replacing equipment and shows that hydrogen blends can be integrated without needing costly upgrades.
Energy and waste reduction Forterra is also making substantial investments in renewable energy, sourcing 70% of electricity from its solar farm in Retford, avoiding 14,000 tonnes of CO2 emissions annually. The 7,000 solar panels at the Desford factory will generate a further 16% of the factory’s energy needs.
in the industry is cement, which is why it is important to explore low-carbon alternatives in concrete production. In partnership with Swedish mining company LKAB, Forterra is pioneering the use of calcined clay as a substitute for traditional cement. Manley explains: “Our calcined clay is produced using recycled brick waste, reducing the need for energy-intensive clinker production. This not only lowers carbon emissions but also promotes the circular economy by moving the reuse of this waste material up the value chain. Early results from our use of calcined clay at the Whittlesey plant have shown a significant carbon saving, with over 2,000 tonnes of CO2 emissions avoided.
“Additionally, we have switched to CEM II cement at several of our plants. The use of alternative admixtures and lower kiln temperatures has allowed us to achieve substantial emissions reductions across our concrete production facilities,” he says As part of the ongoing commitment to decarbonisation, Forterra has also conducted hydrogen blending trials at the Measham Redbank site.
Working closely with Air Products, it tested a 20% hydrogen blend with 80% natural gas
March 2025
www.buildersmerchantsjournal.net
“We are equally committed to reducing packaging waste across our value chain,” Manley says. “By the end of 2025 we aim to have reduced our plastic packaging by 50%, while an innovative packaging solution at Desford already uses 36% less plastic than previous methods. Furthermore, at our Kings Dyke site, we are successfully recycling workwear and PPE, diverting a large portion of textiles from landfill. This supports our waste reduction targets but also promotes a circular economy within our operations.”
Supporting sustainability goals Manley says that the company is also working on helping the industry navigate the stricter carbon emissions standards to be set by the Future Homes Standard in 2025. “Through tools like our U-value calculator and products such as Jetfloor, we are providing builders with the resources they need to meet these new standards while maintaining the thermal efficiency and sustainability of their projects,” he says.
“At Forterra we remain focused on achieving our ambitious sustainability targets and continuing to lead by example in the building products industry. Looking ahead, we are planning further trials with higher hydrogen blends and expect to expand the trials to assess its application across a wider range of clay types. We also plan to invest more in carbon capture and storage technologies to further reduce our emissions.” BMJ
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