Why the UK Highways Should Embrace Roller-Compacted Concrete (RCC)

Unlocking carbon savings, long-term performance, and sustainable resilience for the national road network. 

As the UK accelerates toward net-zero and greater infrastructure resilience, the conversation around road construction materials is becoming increasingly urgent. Asphalt has long been the default choice for highways, but Roller-Compacted Concrete (RCC) is emerging as a compelling alternative, especially for high-duty pavements, strategic road assets, and freight infrastructure. 

Below, we explore why RCC deserves serious consideration, from carbon benefits to life-cycle performance and sustainability gains. 

1. Lower Carbon Footprint: A Significant Advantage 

One of the largest arguments in favour of RCC is its potential for meaningful carbon savings. 

Why? 

• Lower cement content: RCC typically uses lower cementitious material compared to traditional concrete, and can incorporate large proportions of GBFS, fly ash, or other SCMs. 

• No heating required: RCC is placed cold, unlike asphalt, which requires significant energy to heat aggregates and bitumen. 

• Longer service life: Fewer reconstructions = fewer carbon-intensive interventions over time. 

Estimated carbon reduction: Depending on mix design and SCM usage, RCC can deliver 20–40% lower CO₂ emissions than conventional asphalt pavement over a full life cycle. Future adoption of low-carbon cements could push this even further. 

2. Exceptional Durability and Longer Life Span 

When engineered correctly, RCC pavements are known for their resilience. 

Performance advantages: 

• High load capacity: Excellent for HGV routes, industrial estates, ports, and logistics corridors. 

• Resistance to rutting and deformation: A major challenge for asphalt on heavy-traffic corridors. 

• Minimal maintenance: RCC can achieve 30–50 years of service life, compared with typical asphalt design lives of 15–20 years (often less under heavy loading). 

A hybrid design e.g., RCC base with an asphalt surface course, can further extend lifespan while meeting ride-quality requirements. 

3. Lower Whole-Life Cost 

Although RCC can have a slightly higher initial material cost compared to standard asphalt, whole-life economics usually favour RCC. 

Why RCC costs less long-term: 

• Fewer major maintenance cycles 

• Reduced downtime and traffic disruption 

• Superior structural longevity 

• Lower fuel and material inputs over its lifetime 

For asset owners like National Highways or local authorities, whole-life value is increasingly prioritised, making RCC a strong candidate. 

4. Enhanced Sustainability Beyond Carbon 

Sustainability is not just about CO₂. RCC also offers: 

• Ability to incorporate recycling: Crushed concrete, reclaimed aggregates, and industrial by-products can be used at high percentages. 

• Reduced heat and fumes on site: Healthier working environments, fewer VOC emissions. 

• Lower dependency on imported bitumen: Improving material security and resilience. 

As the UK faces rising bitumen prices and availability risks, diversification in pavement materials is becoming strategically important. 

5. Where RCC Makes the Most Sense in the UK 

RCC is particularly suitable for: 

• Heavy goods corridors 

• Freight and logistics hubs 

• Bus depots and park-and-ride facilities 

• Industrial parks 

• Rural strategic routes 

• Car parks and hardstandings 

• Pavement bases in hybrid systems 

For high-speed motorways, RCC is often used as the structural base with an asphalt or thin concrete surfacing, combining strength, smoothness, and durability. 

6. Why Hasn’t RCC Been Widely Adopted Yet? 

Common barriers include: 

• Lack of specification familiarity 

• Perception of “poor finish” (mainly when compared to asphalt, though modern micro-surfacing or thin overlay solves this) 

• Limited domestic case studies 

• Conservative procurement frameworks 

However, international use is accelerating, especially in the US, Canada, Germany, and parts of Asia, demonstrating its viability for modern highways. 

Conclusion: RCC Is a High-Value, Low-Carbon Opportunity for UK Roads 

As the UK targets net-zero and resilience in infrastructure spending, RCC offers a compelling path forward. 

✔ Lower carbon footprint ✔ Longer life span ✔ High load capacity ✔ Lower whole-life cost ✔ Sustainable and resource-efficient ✔ Compatible with hybrid pavement strategies 

Given the scale of the UK road network and the rapidly increasing freight demands, RCC deserves a much larger role in our pavement design toolkit. 

If the industry wants to reduce carbon, improve durability, and future-proof national highways, the question may no longer be “Why use RCC?” but rather: 

“Why aren’t we using more of it already?”