Element 1’s Innovative Approach to Achieving Net-Zero in Construction
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The construction industry is under growing pressure to reduce emissions and adopt sustainable practices. Heavy machinery, which relies heavily on diesel, is a significant contributor to the sector’s carbon footprint, making it a critical area for decarbonisation.
In response, BAM has launched Element 1, a project designed to integrate hydrogen fuel technology into construction site operations. This initiative marks a significant step towards net-zero construction sites, showing that sustainability and productivity can go hand in hand.
How Element 1 is reshaping fuel use on construction sites
Element 1 aims to cut diesel consumption by introducing dual-fuel hydrogen technology. Rather than replacing existing machinery, BAM and its partners have developed a hybrid solution that modifies diesel equipment to run on both diesel and hydrogen. This reduces diesel use by up to 30 per cent, extending the lifespan of machinery while lowering emissions.
Backed by a £4.87 million grant from the Department for Energy Security and Net Zero, the project has brought together leading industry players, including GeoPura, ULEMCo, Plantforce, Flannery, BRE, Skanska, and Reynolds. This collaboration has allowed BAM to move beyond theoretical models, testing the technology in real-world conditions.
With initial trials proving successful, Element 1 is now in active deployment. Four dual-fuel excavators have been trialled on sites in Manchester, Brighouse, and Ravensthorpe, providing valuable data on how the technology performs in different environments. Each site presents unique challenges, helping BAM refine the system based on real-world feedback.
Real-world trials and technological advancements shaping Element 1’s success
BAM’s commitment to decarbonisation extends beyond research—it is actively testing Element 1 technology in the field. Trials have confirmed that hydrogen can be a viable alternative to pure diesel, cutting emissions without sacrificing performance.
A key advantage of the dual-fuel system is its flexibility, allowing operators to switch between hydrogen and diesel as needed. This ensures that construction teams can maintain efficiency, even in areas where hydrogen supply may be limited. Unlike fully electric solutions, which often require entirely new machinery, Element 1 enables companies to retrofit existing equipment, making the transition to sustainable fuels more practical and cost-effective.
As with any new technology, continuous refinement has been essential. Recent software updates have improved hydrogen injection control, enhancing fuel efficiency and reducing diesel consumption further. By incorporating real-time feedback from construction sites, BAM and its partners are optimising the technology for different working conditions.
How HyTANKa™ is supporting hydrogen-powered machinery
One of the biggest challenges in adopting hydrogen-powered construction equipment is refuelling logistics. Unlike diesel, which has well-established infrastructure, hydrogen requires new distribution methods. To address this, BAM and its partners have developed HyTANKa™, a mobile hydrogen refueller designed to transport and distribute hydrogen efficiently across construction sites.
Currently undergoing stringent testing, HyTANKa™ meets high safety standards, allowing hydrogen to be transported via public highways safely. The ability to refuel dual-fuel machines on-site is a crucial step in making hydrogen a practical energy source for construction.
HyTANKa™ is particularly beneficial for remote and temporary construction sites, where fixed hydrogen infrastructure is not an option. By solving one of the biggest barriers to adoption—fuel access—this innovation supports the wider transition to hydrogen-powered construction machinery.
The success of Element 1 has been driven by strong industry collaboration. By uniting hydrogen specialists, construction equipment providers, and contractors, BAM and its partners have developed a practical, scalable solution for reducing emissions on construction sites. This project proves that collective innovation can drive real industry change.
As trials continue, data gathered from Manchester, Brighouse, and Ravensthorpe will provide insights into the long-term feasibility of dual-fuel technology. The findings, set for publication in spring 2025, will help shape future investment and policy around hydrogen fuel technology in construction.
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