On August 18, 2025, a group of academics from the University of Warwick unveiled an ambitious digital roadmap designed to accelerate the UK steel industry’s journey toward net zero emissions. Their research, supported by the InterAct programme and part of the wider Made Smarter Innovation initiative, takes a deep dive into the sector’s most stubborn challenges and offers a blueprint for a greener, more competitive future.
The UK steel industry is a heavyweight in the national economy, comprising over 1,100 companies and contributing £2.3 billion annually, according to the University of Warwick study and as reported by InterAct. Despite its economic clout, the sector is under mounting pressure to shrink its environmental footprint. Steel’s ability to be endlessly recycled is a silver lining, but the harsh reality is that its production remains one of the most energy-intensive industrial processes around. This makes the push for cleaner, more efficient production methods not just a national concern, but a global imperative.
The new research, developed by Dr. Taofeeq Ibn-Mohammed, Dr. Mehmet Chakkol, and Dr. Aitana Uclés Fuensanta from the University of Warwick, with support from Dr. Temidayo Akenroye of the University of Missouri–St. Louis, identifies the most pressing barriers to adopting Industrial Digital Technologies (IDTs) in the steel sector. These digital tools—ranging from smart sensors to advanced data analytics—hold the promise of transforming how steel is made, potentially slashing both energy usage and carbon emissions.
But the path to digital transformation is anything but smooth. The team’s research highlights 12 critical barriers standing in the way, including investment uncertainty, skills shortages, regulatory complexity, and environmental considerations. To unravel these interlocking challenges, the researchers employed Interpretive Structural Modelling (ISM) and MICMAC analysis, mapping out a seven-layer hierarchical framework that reveals how these obstacles interact and which should be tackled first.
“Our research provides targeted, actionable recommendations that empower decision-makers to focus their efforts where they’ll have the greatest impact,” Dr. Ibn-Mohammed explained, as quoted by InterAct. “A strategic blend of policy reform, technological innovation, organisational change, and smart economic planning is key to overcoming these barriers and building a greener, more competitive steel industry.”
The roadmap does more than just identify what’s holding the sector back—it offers a practical guide for policymakers and industry leaders to prioritize interventions. According to Dr. Aitana Uclés Fuensanta, the project’s lead researcher, “This is the first empirical analysis of its kind to map the causal relationships between barriers to IDT adoption. Our insights will enable stakeholders to prioritise action, share best practices, and drive meaningful progress toward net zero.”
The research findings have already begun to make waves. At AISTech, the Iron and Steel Technology Conference in the United States, the work was met with praise from international stakeholders, highlighting its potential relevance not just within the UK but across the global steel community. The team is now preparing a dedicated practitioner’s report to further inform industry strategy and foster cross-sectoral collaboration.
The urgency of this work cannot be overstated. While steel’s recyclability is a major asset, the energy required to produce new steel remains a sticking point. As noted in the study, the drive toward greener, more efficient practices is both a national and global priority, given the sector’s significant contribution to CO₂ emissions. The UK government and industry leaders are under increasing scrutiny to deliver on climate commitments, and digital innovation is being hailed as a crucial lever for change.
What sets this research apart is its holistic approach. Rather than treating technological adoption as a purely technical challenge, the team recognizes the importance of human and organizational factors. Skills shortages, for example, are not just a matter of training but also of attracting new talent to an industry that’s often seen as old-fashioned or polluting. Regulatory complexity, too, can stifle innovation if policies aren’t adaptive enough to accommodate new technologies.
This is where the InterAct programme comes into play. As a Made Smarter Innovation-funded, Economic and Social Research Council-led network, InterAct brings together economic and social scientists, UK manufacturers, policymakers, and digital technology providers to address the human issues arising from technological change. The network has engaged more than 2,000 stakeholders across 70-plus events and boasts a community of over 750 members, acting as a bridge between industry, policy, and academia.
InterAct’s impact extends beyond steel. The methodologies developed in this research are already being applied to other sectors, including ceramics and glass, signaling a broader shift toward industrial sustainability across the UK. As Dr. Ibn-Mohammed put it, “By addressing both the regulatory and operational challenges facing the sector, we can enable smarter, more adaptive policies and unlock the full potential of digital transformation in UK manufacturing.”
The network’s influence is growing, too. InterAct recently secured almost £1 million in additional funding aimed at supporting small and medium-sized enterprises (SMEs) in the UK as they adopt new industrial digital technologies to improve sustainability. This investment is expected to further accelerate the pace of change, particularly among businesses that may lack the resources of larger players.
Professor Jill MacBryde, InterAct Co-Director from the University of Strathclyde, underscored the significance of the University of Warwick team’s work, stating, “The work undertaken by the University of Warwick team represents a crucial step towards a more sustainable future for the steel sector.”
As the UK steel industry looks to the future, the message from researchers is clear: digital transformation isn’t just about adopting the latest gadgets or software. It’s about reshaping the industry’s entire ecosystem—policies, skills, investments, and mindsets—to meet the demands of a low-carbon world. The new roadmap offers a way forward, but real change will require collaboration at every level, from shop floor workers to government ministers.
Amid the complexity and challenges, there’s a note of optimism. The UK’s leadership in industrial sustainability innovation is being reinforced, not just through high-level strategy but through practical, evidence-based solutions. And as the methodologies spread to other industries, the ripple effects could be felt far beyond steel, helping to build a greener, more resilient manufacturing sector for generations to come.
