Environmental Product Declaration

Transcription

1 Environmental Product Declaration According to ISO and ISO Standard, Medium and High & Ultra High Density Spray-applied Fire-Resistive Materials (SFRMs) Commissioned by GCP Applied Technologies Inc.

2 ASTM International Certified Environmental Product Declaration This document is a Type III environmental product declaration for Standard, Medium and High & Ultra High Density Fireproofing Products, as manufactured at all three GCPAT SFRM facilities in North America (both United States and Canada). As such the EPD is categorized as a North American corporate average EPD representing multiple SFRM manufacturing facilities. This declaration has been prepared in accordance with ISO 14025, ISO 21930, ISO 14040/44, ASTM Product Category Rule (PCR) for Spray-applied Fire-Resistive Materials (SFRM) and ASTM General Program Instructions for Type III EPDs. Environmental Product Declaration Summary General Information Owner of the EPD GCP Applied Technologies Inc. 62 Whittemore Avenue Cambridge, Massachusetts USA Link (URL): GCPAT is headquartered in Cambridge, Massachusetts, USA, and has manufacturing, R&D and technical services sites in more than 40 countries on six continents. Sales offices and distributors are present around the world as GCPAT serves customers in over 110 countries. GCPAT was formed in February 2016 by the spin-off of W. R. Grace & Co.'s construction products segment and its packaging technologies business. The owner of the declaration is liable for the underlying information and evidence. Corporate and SFRM Manufacturing Facilities GCP Applied Technologies Inc., Corporate 62 Whittemore Avenue Cambridge, Massachusetts USA Ajax, Canada 294 Clements Rd. West Ajax, Ontario L1S 3C6

3 Corporate and SFRM Manufacturing Facilities (continued) Product Name Product Definition Product Category Rule (PCR) Irondale, United States 2601 Commerce Blvd. Irondale, Alabama Santa Ana, United States 2500 & 2502 S. Garnsey Street Santa Ana, California Spray-applied Fire-Resistive Material (SFRM), UN CPC SFRM is composed primarily of binding agents such as cement or gypsum and often contains other materials such as mineral wool, quartz, perlite, vermiculite, or bauxite along with various other ingredients [1]. ASTM 2017, Product Category Rules (PCR) For Preparing an Environmental Product Declaration for: Spray-applied Fire- Resistive Materials (SFRM) [1]. Certification Period Declared Unit 1,000 kg of SFRM ASTM Declaration Number EPD-060 EPD Information Program Operator Declaration Holder ASTM International Environmental Product Declarations 100 Barr Harbor Drive, West Conshohocken, PA GCP Applied Technologies Inc. Product group Spray-applied Fire-Resistive Material Declaration Type Date of Issue Period of Validity 5 years Declaration Number EPD-060 A Product Stage or Cradle-to-gate EPD of GCP Applied Technologies production of standard, medium and high & ultra-high density spray-applied fire-resistive material. The declaration presents a weighted average profile for all three North American facilities operated by GCP Applied Technologies Inc. that manufacture SFRMs. Product activities covered include the raw material supply, transport and manufacturing (modules A1 to A3). The declaration is intended for Business-to-Business (B-to-B) communication. Applicable Countries United States and Canada

4 Content of the Declaration The declaration follows Section 11, Content of EPD, ASTM 2017, Product Category Rules For Preparing an Environmental Product Declaration for: Spray-applied Fire-Resistive Materials [1]. This EPD was independently verified by ASTM in accordance with ISO 14025: Internal External X Tim Brooke 100 Barr Harbor Drive, PO Box C700 West Conshohocken, PA , USA EPD Project Report Information EPD Project Report Prepared by A Cradle-to-Gate Life Cycle Assessment of GCP Applied Technologies Inc. Standard, Medium and High & Ultra High Density Spray-applied Fire-Resistive Materials (SFRMs). March Lindita Bushi Ph.D. and Jamie Meil Athena Sustainable Materials Institute 119 Ross Avenue, Suite 100 Ottawa, Ontario, K1Y 0N6, Canada info@athenasmi.org This EPD project report was independently verified by in accordance with ISO and the reference PCR: PCR Information Program Operator Thomas P. Gloria, Ph.D. Industrial Ecology Consultants 35 Bracebridge Rd. Newton, MA t.gloria@industrial-ecology.com ASTM International Reference PCR Product Category Rules (PCR) For Preparing an Environmental Product Declaration for: Sprayapplied Fire-Resistive Materials (SFRM) [1]. Date of Issue 03/2017 PCR review was conducted by: Thomas P. Gloria, Industrial Ecology Consultants (chairperson) Jeffrey E. Gould, FM Approvals Karl D. Houser, Intertek Building and Construction

5 1 PRODUCT IDENTIFICATION 1.1 PRODUCT DEFINITION Spray-applied fire-resistive materials (UN CPC 54650) is composed primarily of binding agents such as cement or gypsum and often contains other materials such as quartz or bauxite along with various other ingredients. The other materials are used to help lighten the solution or to add air as an insulator. Chemical hardeners are sometimes used to either speed up hardening or to make the final fireproofing harder than the original [1]. Passive fire protection materials (commonly referred to as fireproofing) are used to prevent or delay the failure of steel and concrete structures exposed to fire. These materials are intended to insulate the structural members during the event of a fire, delaying any loss of the integrity of the structural members. There is an array of available fireproofing materials that can be used depending upon the specific application. Applied fireproofing is available as a wet or dry formula. It is typically sprayed but can also be troweled on. The fireproofing is generally delivered as a dry powder in bag, which is then mixed with water in the field. Modern formulas are asbestos-free and don't contain free crystalline silica [1]. This is a company specific EPD representing an array of available SFRMs produced at three of GCPAT s facilities located in North America and produced to various specifications as noted in Table PRODUCT STANDARDS The physical characteristics of SFRM are determined according to various ASTM standards such as, but not limited to [1]: E736/E736M, Standard Test Method for Cohesion/Adhesion of Sprayed Fire- Resistive Materials Applied to Structural Members E605/E605M, Standard Test Methods for Thickness and Density of Sprayed Fire- Resistive Material Applied to Structural Members E759/E759M-92(2015)e1 Standard Test Method for Effect of Deflection on Sprayed Fire-Resistive Material Applied to Structural Members E760/E760M-92(2015)e1 Standard Test Method for Effect of Impact on Bonding of Sprayed Fire-Resistive Material Applied to Structural Members E761/E761M-92(2015)e1 Standard Test Method for Compressive Strength of Sprayed Fire-Resistive Material Applied to Structural Members E859/E859M-93(2015)e1 Standard Test Method for Air Erosion of Sprayed Fire- Resistive Materials (SFRMs) Applied to Structural Members E937/E937M-93(2015)e1 Standard Test Method for Corrosion of Steel by Sprayed Fire-Resistive Material (SFRM) Applied to Structural Members.

6 1.3 TECHNICAL DATA, MATERIAL CONTENT, AND PACKAGING Tables 1 summarize key technical data for GCPAT SFRMs for the 2015 reference year (12 months). GCPAT SFRMs are classified in three major sub-categories based on the dry density minimum average values in pcf (pound per cubic foot). Full material selection guide and literature and the material safety data sheets are available for each of these fireproofing materials on the web at As required in the ASTM PCR [1], a weighted average generic formulation is calculated for each representative sub-category that reflect the relative annual production volumes for the relevant GCPAT brand products (Table 1, last column) per sub-category. Table 1. Technical Data for Technical Data for GCPAT SFRMs Primary Binding Agent GCPAT SFRM- Sub-category Dry density, minimum average in pcf (kg/m 3 ) GCPAT Brand Names Gypsum - based Standard density 15 (240) MK Patch MK1000HB MK1000HB Ext Set MK10HB MK10HB Ext Set MK6 Ext Set MK6GF MK6HY MK6HYCE MK6HY Ext Set MK6HYEXP MK6S MK6SCE RG Cement- or gypsumbased or a blend Cement- based Medium density 22 (352) SK3 Z106G Z106HY Z3306 Z3306 Gray Z3306 White High & ultra-high density 40 (640) Z146 Z146T Z156 Z156PC Z156T Z164PC Table 2 shows the weighted average generic formulations for all three sub-categories of GCPAT fireproofing materials as produced at GCPAT s three manufacturing locations. For reasons of confidentiality a portion of each SFRM is reported as additives. Table 3

7 shows the amount of packaging materials per 1,000 kg of GCPAT SFRMs. Paper sacks are used for transporting powder materials, such as fireproofing materials. The sacks are typically made of high quality and weight kraft paper, usually virgin fiber. Table 2. Weighted Average Generic Formulations for Standard, Medium, High & Ultra High Density SFRMs Standard Density Medium Density High & Ultra High Density Material composition % Material composition % Material composition % Stucco (CaSO4*½H2O) 86% Portland cement 66% Portland cement 41% Stucco (CaSO4*½H2O) 20% Bauxite 49% Clay 1% Clay 4% Clay 4% Rest- additives 13% Rest- additives 10% Rest- additives 6% Total 100% Total 100% Total 100% Note: Material safety data sheets are available for all SFRMs at Table 3. Packaging Materials for GCPAT SFRMs Packaging material Quantity Units (per 1,000 kg SFRM) Paper sacks 2.2E-02 metric ton Corrugated paper 3.0E-04 metric ton Total 2.2E-02 metric ton 2 DECLARED UNIT and LIFE CYCLE STAGES The declared unit is the basic reference flow set by the ASTM PCR for the assessed products. According to the ASTM PCR for SFRM, the declared unit of this study is defined as 1,000 kg of SFRM [1]. As illustrated in Figure 1, the system boundary of construction products is typically characterized by the temporal flow of its life cycle i.e. Product, Construction Process, Use, and End of Life stages. The various processes that occur at each stage are classified and grouped in information modules (or simply "modules"), labeled with alpha-numeric designations "A1" through "C4". A declared unit is defined for EPDs covering cradle-togate, or the production stage (shown infilled green in Figure 1), which consists of three modules: A1 Raw Material Supply; A2 Transport (to the manufacturer); and A3 Core Manufacturing. This study focuses on the product stage only and no Module D credits or burdens are included in the assessment or EPD. Included and excluded product stage processes are listed in Table 4.

8 Figure 1 Life Cycle Modules Included and Excluded from the System Boundary Table 4: Product stage system boundaries Included and excluded processes Product Stage A1-A3 Modules Included A1 Product Stage [1]: Extraction and processing of input raw materials used in weighted average generic formulations for standard, medium, high & ultra-high density SFRMs, including fuels used in extraction and transport within the process. A2 Product Stage [1]: Weighted average transportation of input raw materials (including recovered materials) from extraction site or source to manufacturing site and including empty backhauls and transportation to interim distribution centers or terminals. A3 Product Stage [1]: Manufacturing of the SFRMs, including all energy and materials required and all emissions and wastes produced. This includes: - Packaging, including transportation and waste disposal, to make SFRMs ready for shipment; - Average transportation from manufacturing site to landfill for on-site wastes, including empty backhauls and the waste disposal process. The A3 module includes grinding, mixing, blending, pneumatic conveying, high speed auger packaging, lighting and heating, ventilation and air conditioning, operation of environmental equipment (baghouses and bin vents), on-site transportation (loading and unloading) and storage of SFRMs. Excluded -Production, manufacture, and construction of manufacturing capital goods and infrastructure; -Production and manufacture of production equipment, delivery vehicles, and laboratory equipment; -Personnel-related activities (travel, furniture, and office supplies); and - Energy and water use related to company management and sales activities that may be located either within the factory site or at another location.

9 3 CUT-OFF RULES, ALLOCATION RULES AND DATA QUALITY REQUIREMENTS Cut-off Rules No cut-off criteria were applied in the study. All input/output data reported by the three GCPAT SFRM manufacturing facilities were included in the LCI modelling. None of the reported flow data were excluded based on the cut-off criteria. Allocation Rules Allocation rules, as specified in ASTM PCR for SFRM, section 7.5 were followed [1]. Recycled and recovered materials such as hammermilled newsprint and post-industrial polystyrene are considered raw materials. Only the materials, water, energy, emissions, and other elemental flows associated with reprocessing, handling, sorting, and transportation from the generating industrial process to their use in the production process are considered. Any allocations before reprocessing are allocated to the original product. Allocation related to transport are based on the mass of transported product. Mass was deemed as the most appropriate physical parameter for allocation used for the SFRMs manufacturing system to calculate the input energy flows (electricity, natural gas and propane), packaging materials and waste flows per declared unit of 1,000 kg of SFRM. Data Quality Requirements Data quality requirements, as specified in ASTM PCR for SFRM, section 7.1, were observed [1]. Precision: GCPAT SFRM facilities, through measurement and calculation, collected primary input and output data specific to their production of SFRMs. For accuracy, the LCA team individually validated all facility specific gate-to-gate input and output data. Completeness: All relevant, specific processes, including inputs (raw materials, energy and ancillary materials), outputs (emissions and production volume) and SFRM generic formulations were considered. The relevant background materials and processes were based on the North American industry specific LCA and EPDs (for stucco and Portland cement binding agents), US LCI Database (adjusted for known data placeholders), ecoinvent LCI database v3.2, and modeled in SimaPro software v.8.3, February Consistency: System boundaries, allocation and cut-off rules have been uniformly applied across the product stage modules (A1 to A3). The study predominantly relies on three major upstream materials (stucco, Portland cement and bauxite) and two secondary data sources (US LCI and ecoinvent 3.2 databases); ecoinvent LCI datasets were adjusted uniformly for the North American geography (electricity grid, fuel combustion). Crosschecks concerning the plausibility of mass and energy flows were continuously conducted. Reproducibility: Internal reproducibility is possible since the data and the models are stored and available in Athena LCI database for GCPAT SFRM developed in SimaPro, A high level of transparency is provided throughout the EPD report as the LCI profiles and data are presented for the declared products. Key secondary (generic) LCI data sources are summarized in Table 6, EPD report. Uncertainty: Uncertainty associated with the LCA model and results is considered low given the high representativeness of primary data collected for major input materials (A1), transport (A2) and manufacturing (A3). Representativeness: The representativeness of the data is summarized as follows. Temporal representativeness is characterized as high. Primary data for SFRM manufacturing process were collected at three GCPAT SFRM manufacturing facility for the reference year 2015 (12 months). Primary data are used for stucco and Portland cement binding agents as published by Gypsum Association, US Portland Cement Association (PCA) and Cement Association of Canada (CAC), respectively. All secondary data come from the SimaPro 8.3, February 2017 (US LCI database, adjusted and ecoinvent v.3.2 database for US and global, 2016).

10 Data Quality Requirements (continued) Representativeness (continued): Geographical representativeness is characterized as "high". Primary data for SFRM manufacturing were collected specific to North America. North American specific or adjusted generic data were used to complete the LCI modeling. Generic data is publicly available and may be average or specific. For minor imported additives, generic LCI datasets were adjusted for the region-specific electricity grids. Technological representativeness is characterized as high. Both primary data for major binding agents and SFRM manufacturing process were modeled to be specific to the technologies or technology mixes under study and represent contemporary North American technologies. 4 LIFE CYCLE ASSESSMENT RESULTS This section summarizes the results of the life cycle impact assessment (LCIA) and cumulative inventory metrics based on the cradle-to-gate life cycle inventory inputs and outputs analysis. As per the ASTM PCR, Section 8, US EPA s Tool for the Reduction and Assessment of Chemical and Other Environmental Impacts (TRACI, version 2.1) impact categories are used as they provide a North American context for the mandatory category indicators to be included in this EPD. These are relative expressions only and do not predict category impact end-points, the exceeding of thresholds, safety margins or risks. Total primary and sub-set energy consumption was compiled using a cumulative energy demand model. Material resource consumption and generated waste reflect cumulative life cycle inventory flow information. Table 5 shows the aggregated product stage total, for standard, medium, high and ultrahigh density SFRMs. Figures 2, 3 and 4 present the EPD results for 1,000 kg of standard, medium and high & ultra-high density SFRMs by information module, in percentage basis, respectively. Table 5: Product Stage EPD Results for 1,000 kg standard, medium, high & ultra-high density SFRMs Environmental Indicator Unit Standard Density (min 15 pcf) Medium Density (min 22 pcf) High & Ultra High Density *) (min 40 pcf) Global warming potential, GWP kg CO2 equiv Acidification potential, AP kg SO2 equiv Eutrophication potential, EP kg N equiv Smog creation potential, POCP kg O3 equiv

11 Environmental Indicator Unit Standard Density (min 15 pcf) Medium Density (min 22 pcf) High & Ultra High Density *) (min 40 pcf) Ozone depletion potential, ODP kg CFC-11 equiv. 1.2E E E-04 Total primary energy consumption Non-renewable, fossil, PENRfossil Non-renewable, nuclear, PENRnuclear Renewable, solar, wind, hydroelectric, and geothermal, PER-SWHG Renewable, biomass, PERbiomass MJ, HHV 4,176 8,830 7,439 MJ, HHV MJ, HHV MJ, HHV Material resources consumption Non-renewable materials, NRMR kg 1,106 1,287 1,190 Renewable materials, RMR kg Net fresh water consumption, NFW m Waste generated Non-hazardous waste, NHW kg Hazardous waste, HW kg

12 Figure 2 Product Stage EPD Results for 1,000 kg of standard density SFRM by Information Module- % Basis

13 Figure 3 Product Stage EPD Results for 1,000 kg of medium density SFRM by Information Module- % Basis Figure 4 Product Stage EPD Results for 1,000 kg of high and ultra-high density SFRM by Information Module- % Basis

14 5 INTERPRETATION The EPD results represent a cradle-to-gate EPD per 1,000 kg of standard, medium and high & ultra-high density SFRMs as manufactured at GCPAT SFRM manufacturing facilities during the reference year For standard density SFRM, raw material supply (A1) dominates the LCIA results and nonrenewable, fossil accounting for between 36% and 66% of the total environmental burdens apart from ODP (2%). Inbound transportation (A2) is the second largest contributor to the declared product impacts and accounted for 52% of the total POCP. Except for ODP and EP, core manufacturing (A3) accounted for less than 21% of the overall impacts. Paper bags production used for packaging (A3) contributes 98% and 99% of the total ODP and RMR, respectively. Both A3 electricity consumption and paper bags production contribute up to 58% of the total EP (A3). Raw material supply (A1) also dominates NRMR, NFW and HW. Primary energy consumption is predominately fossil fuels based at 83%. Nuclear and renewable energy make up 14% and 3%, respectively. For medium density SFRM, raw material supply (A1) dominates the LCIA results and nonrenewable, fossil accounting for between 73% and 80% of the total environmental impact; the exception is ODP at 14%. Inbound transportation (A2) is the second largest contributor to the declared product impacts but accounted for less than 22% of the overall impact. Apart from ODP and EP, manufacturing (A3) accounted for less than 7% of the overall impacts. Paper bags production used for packaging (A3) contributes 86% and 73% of the total ODP and RMR, respectively. Both A3 electricity consumption and paper bags production contribute up to 21% of the total EP (A3). Raw material supply (A1) also dominates PENR-nuclear, PER-SWHG, PER-biomass, NRMR, NFW and HW. Primary energy consumption is predominately fossil fuels based at 84%. For high and ultra-high density SFRM, raw material supply (A1) again dominates the LCIA results and non-renewable, fossil accounting for between 67% and 81% of the total environmental impacts with ozone depletion at 10% again the exception. Inbound transportation (A2) is the second largest contributor to the declared product impacts and generally accounted for less than 27% of the overall impacts. Apart from ODP and EP, manufacturing (A3) accounted for less than 9% of the overall impacts. Paper bags production used for packaging (A3) contributes to 90% and 82% of the total ODP and RMR, respectively. Both A3 electricity consumption and paper bags production contribute up to 23% of the total EP (A3). Raw material supply (A1) also dominates PENR-nuclear, PER-SWHG, PER-biomass, NRMR, NFW and HW. Primary energy consumption is predominately fossil fuels based at 84%. Nuclear and renewable energy make up 10% and 6%, respectively.

15 6 ADDITIONAL AND ENVIRONMENTAL INFORMATION Standard, medium and high & ultra-high density SFRMs use between 2% to 7% recovered materials (hammermilled newsprint and post-industrial polystyrene). 7 DECLARATION TYPE GCPAT SFRM EPD is categorized as follows: - A company specific product EPD, from the manufacturer s plants. This declaration presents a weighted average EPD for three SFRM North American facilities operated by GCPAT. Product activities covered include the raw material supply, transport and manufacturing (modules A1 to A3). The declaration is intended for Business-to- Business (B-to-B) communication. 8 DISCLAIMER The following ISO statement indicates the EPD comparability limitations and intent to avoid any market distortions or misinterpretation of EPDs based on the ASTM PCR for SFRM: - EPDs from different programs (using different PCR) may not be comparable. - Declarations based on the ASTM PCR for SFRM are not comparative assertions; that is, no claim of environmental superiority may be inferred or implied. 9 EPD Explanatory Material For any explanatory material regarding this EPD, please contact the program operator. ASTM International Environmental Product Declarations 100 Barr Harbor Drive, West Conshohocken, PA ,

16 11 REFERENCES 1. ASTM 2017: Product Category Rules (PCR) For Preparing an Environmental Product Declaration for: Spray-applied Fire-Resistive Materials (SFRM), (UN CPC AND/OR CSI MASTERFORMAT DIVISION AND ), 2. ASTM Program Operator for Product Category Rules (PCRs) and Environmental Product Declarations (EPDs), General Program Instructions v.7, 06/14/ ISO 21930: 2007 Building construction Sustainability in building construction Environmental declaration of building products. 4. ISO 14025: 2006 Environmental labeling and declarations - Type III environmental declarations - Principles and procedures. 5. ISO 14044: 2006 Environmental management - Life cycle assessment - Requirements and guidelines. 6. ISO 14040: 2006 Environmental management - Life cycle assessment - Principles and framework. 7. ISO 14021:1999 Environmental labels and declarations - Self-declared environmental claims (Type II environmental labelling) 8. EN 15804:2012 Sustainability of construction works Environmental product declarations Core rules for the product category of construction products. 9. Athena Institute 2017, A Cradle-to-Gate Life Cycle Assessment of GCP Applied Technologies Inc. Standard, Medium and High & Ultra High Density Spray-applied Fire- Resistive Materials (SFRMs). March 2017.