PORCELANOSA. DAPc Medium porcelain stoneware C. Y..a, I ENGtNYERS O'EDIFICACIO OE BARCELONA

Transcription

1 DAPc Medium porcelain stoneware ENVIRONMENTAL PRODUCT DECLARATION DAPc PRODUCT Medium porcelain stoneware C COMPANY PRODUCT DESCRIPTION The product covered is medium stoneware that includes different models of porcelain stoneware. IN ACCORDANCE WITH ISO STANDARDS and PCR REFERENCE RCP 002 Productos de revestimiento cerámico Version 1 (2010) PRODUCTION PLANT Carretera N-340, Km 56 Villarreal, Castellón VALIDITY From: To: The validity of DAPc is subject to the conditions of DAPc regulations. The relevant version of this DAPc is included in the register kept by the CAATEEB; for more information, consult the system s website: #~~ COL-LEOI D'APARELLADORS. AROUITECTES TECNICS Y..a, I ENGtNYERS O'EDIFICACIO OE BARCELONA 1

2 DAPc Medium porcelain stoneware Blank page COl. l.legi O"APAftEI.LAOOltS. AROUITIECTIES TtCNICS I ENGIN'f'tltS O"EOIFICACK) ot,.ucu.ona 2

3 DAPc Medium porcelain stoneware Environmental Product Declaration: Medium stoneware Executive summary DAPc SYSTEM Environmental product declarations in the construction sector SYSTEM ADMINISTRATOR Col legi d Aparelladors, Arquitectes Tècnics i Enginyers d Edificació (CAATEEB) C. Bon Pastor, 5, Barcelona HOLDER OF THE DECLARATION, Carretera N-340, Km 56, Villarreal, Castellón DECLARATION CARRIED OUT BY: GiGa (Escola Superior de Comerç Internacional-Universitat Pompeu Fabra) Calle Pujades 1, 08003, Barcelona - Spain DECLARATION NUMBER DAPc PRODUCT DECLARED Medium stoneware PRODUCT DESCRIPTION The product in question is a medium porcelain stoneware that includes different models of stoneware with a variability of +/- 10% between input and output. REGISTRATION DATE VALIDITY This verified declaration authorizes the holder to use the DAPc eco-label logo. The declaration is applicable exclusively to the product in question and for five years as of the date of registration. Porcelanosa is responsible for the information contained in this declaration. ENDORSED BY THE CAATEEB Rosa Remolà, President of the CAATEEB ~,,,,,,.. COI...L CJI O'APARELLAO RS, ~~ ECTES T~CNICS I ENGINVERS O'EOI r - - SARGlil.QNA ~ / ~ I ENDORSED BY AUTHORIZED VERIFIER Ferran Pérez, accredited auditor of the ITEC r ma f,e_c::. -~ -- ~ CClnmucd6 -t-' This environmental product declaration complies with ISO standards and and contains information of an environmental nature about the life cycle of the Medium stoneware product manufactured by Porcelanosa at its plant in Villarreal (Castellón). This declaration is based on the document RCP 002 Productos de revestimiento cerámico Version COL-LEOI D'APARELLADORS. AROUITECTES TECNICS I ENGtNYERS O'EDIFICACIO OE BARCELONA 3

4 DAPc Medium porcelain stoneware Environmental Product Declaration for Medium stoneware 1. Description of the product and its use The product in question is a Medium porcelain stoneware that includes different models of stoneware with a variability of no more than 10% between input and output. It includes the following models: Water absorption group BIb and BIa (dry pressed with AA of between 0.5 and 3% and < 0.5% respectively) Commercial name: STON-KER / PAR-KER / STON-KER FACHADAS / PAVIMENTOS Nominal formats (cm): 14.3x120x1.2 / 19.3x120x1.2 / 29.4x120x1.2 / 18x65.9x1 / 43.5x43.5x1 / 43x65.9x1 / 59.6x59.6x1.1 / 80x80x1.2 / 59.6x120x1.2 Average weight: 24 kg/m 2 The principal recommended use for this product is to tile floors and/or clad walls and façades, both interior and exterior. 2. Description of the life cycle phases 2.1. Manufacture (A1, A2 and A3) Raw materials (A1 and A2) The Medium stoneware product basically comprises clay, sand and feldspar with an enamel layer mainly comprising feldspar, carbonate, silicate and kaolin, among others. The raw materials used have different origins (provincial, national, Turkey, Ukraine and United Kingdom). This variation is due to the inability to obtain these materials from a single source. The raw materials from outside Spain are transported by freighter to the port of Castellón and then by truck to the plants. For marine transport, a transoceanic freighter was chosen, with transport distance differing according to the source (Turkey, UK, Ukraine). All the raw materials are transported in bulk, i.e., they do not require packaging materials. Manufacture (A3) Once at the factory, the raw materials are transported to the interior of the plant and stored individually in hoppers that dispense the amount of each raw material to start the process. Once the mix has been made, it is subjected to the processes of milling (or grinding) and then spraying. This stage of the production process serves to produce a homogeneous mixture of the various components with a given particle size and prepares it for moulding the tiles. The wet milling is carried out by using a constantly rotating ball mill. 4

5 DAPc Medium porcelain stoneware The spraying process eliminates excess moisture from the slip. The slip is introduced into the atomizer by sprays that pulverize it and, in contact with a flow of hot air, it dries, becomes atomized and turns into powder, which falls due to gravity. The atomized powder is stored in silos. The company employs a system of combined heat and power for the atomizer. The cogeneration process generates electricity using residual heat produced by combustion, by means of a system of steam turbines and alternators. In a cogeneration plant with the use of a fuel such as natural gas, hot air is generated by a burner, and electricity by a turbine. Both the electrical energy power generated and the hot air are incorporated and used, in part, in the atomization process, thereby reducing the electrical requirements. The tile is then given the desired form. The flat tiles are moulded in simple dry presses that apply flat unidirectional pressure, applied only on one surface of the tile. When removed from the press, the tiles are partially dried in vertical driers to further reduce moisture content, thereby doubling or tripling their mechanical resistance, prior to subsequent processing. Then the temperature of the tile is reduced to a relatively low temperature and the rough edges are removed (the edges are sanded). Shortly after being removed from the drier, the tiles are given one or several coats of glaze. They are treated in this way to give the surface of the fired product a series of technical and aesthetic properties, such as: Impermeability Ease of cleaning Shine and colour Surface texture Chemical resistance Mechanical resistance The first phase before the application of ceramic glazes is the formulation and preparation thereof. Glazes are manufactured at a plant outside Porcelanosa. On the basis of a given oxide composition, the appropriate raw materials are chosen to produce the chemical composition and mineralogical structure that produce the final properties. They principally comprise silica and quartz, followed by oxidizing agents, alkalis, carbonates and zinc oxides (to give particular characteristics of opacity and shine to the frit). These raw materials are mixed and wet milled to produce a slip similar to the one prepared for the tile itself, but with a smaller particle size and a higher percentage of water. The glazing operation involves the successive application of enamel suspension. The glazing line consists of a system of belts driven by pulleys, onto which the ceramic tiles are automatically placed as they emerge from the dryer. Organized along this belt is the necessary equipment to apply the slip and the glaze, both in the form of slurry on the tile support, using a continuous glazing compartment. Then the desired decoration is applied. In this phase, the patterns and designs are applied to the tiles, which are stored in a warehouse before they are put into the kilns. 5

6 DAPc Medium porcelain stoneware The firing is the most important stage of the production process of ceramic tiles, as this is when the previously moulded tiles undergo a fundamental modification of their properties. The tiles are unloaded from the wagons onto a conveyor belt that takes them into the kilns. Once fired, the tiles are transported to the classification station, where an aesthetic (visual) and dimensional examination is carried out. The dimensional examination consists of determining deviations in length and width, orthogonality, straightness of sides and flatness of surface by means of an optical measurement system. The tiles are then packaged. Some series of tiles are taken away to be rectified by grinding, thereby ensuring perfect edges before they are classified. The tiles that meet standards (or have been rectified) are packaged using cardboard, pallets and polyethylene. Once the pallet is made up, it is stored in the logistics area of the plant. To reduce atmospheric emissions, bag filters and wet filters are used, comprising a textile membrane that is permeable to gases but retains the dust in the former case and a curtain or recycled water shower that removes powdered particles in the latter. The tile factory has a closed system of water reuse. Water may be lost by evaporation or by being retained in the product (before ultimately evaporating). To make up for this loss, well water is brought in for the production process. The water is treated using a physical-chemical process and is reintroduced in the grinding and atomization processes Construction Transporting the product (A4) Porcelanosa produces tiles that are commercialized both nationally (46%) and in Europe (33%) and the rest of the world (21%). The most frequent destinations are: National: Madrid, Barcelona, Valencia, Seville, Saragossa, Málaga, Bilbao and Castellón (province) Europe: France, Great Britain, Italy and Eastern European countries Rest of the world: USA, Australia, Japan, China and South America (Argentina) In keeping with the data provided by Porcelanosa, there are three transport scenarios for the finished products. 6

7 DAPc Medium porcelain stoneware Table 1. Scenarios for transport of the product to the place of installation Destination Type of transport Percentage (%) Spain 27 t truck 46 Europe 27 t truck 33 Rest of the world Transoceanic freighter 21 Total 100 For transcontinental transport, medium-sized transoceanic freighters are considered appropriate. All the models used are included in the database [GaBi 4.3]. The estimated distances between the tile factories and the place of installation are: km and 2,000 km for products installed in Spain and Europe, respectively. - 5,000 km for products transported to and installed in the rest of the world Process of installing the product and construction (A5) Once the product is unpacked, it can be installed. According to the data obtained and with a view to applying a real scenario, it is established that installation calls for the use of quick-setting mortar (CaSO4). Tile adhesives are cement-based adhesives comprising a mixture of hydraulic binders, mineral fillers and organic additives, mixed with water or added liquid just before use. They consist of a mixture of white or grey cement, siliceous mineral fillers and/or limestone and organic additives, water retainers, water redispersible polymers, rheology modifiers, fibres, etc Use of the product The use phase is divided into the following modules: Use (B1) Maintenance (B2) Repair (B3) Replacement (B4) Rehabilitation (B5) Use of operational energy (B6) Use of operational water (B7) Once installed, the medium stoneware product requires no further energy input for use, nor does it call for maintenance, except normal cleaning operations. For this reason, of all the modules listed above, only the environmental impacts attributable to product maintenance are applicable (module B2). 7

8 DAPc Medium porcelain stoneware According to Porcelanosa, the useful life of the product is the same as that of the building in which it is used; provided it is correctly installed, it is a lasting product. - Maintenance (B2) The product should be cleaned with a damp cloth. If the surface is dirty or greasy, cleaning agents such as detergents or bleach may be added. This study considers the consumption of water and disinfectant for a scenario of residential use. Scenario 1: residential use 0.03 kg of detergent and 5 l of water are used to wash 50 m 2 of floor tiles, once a week. Table 2. Scenarios for the maintenance of 1 m 2 of medium stoneware product Cleaning products Scenario 1 Water (kg/wash) 0.1 Detergent (kg/wash) Frequency of washing (num. of times) End of life The end-of-life phase includes the following modules: - Deconstruction and demolition (C1) Once it reaches the end of its useful life, the product will be removed, either in the framework of rehabilitation of the building or during its demolition. In the case of the demolition of a building, the impacts attributable to the removal of the product are negligible. - Transport (C2) The product waste is transported by truck in compliance with Euro III norms, to its destination at a distance of 50 km. In this estimation of the 50 km between the demolished building and the closest landfill site, only the Spanish market has been taken into account, extrapolating the results to the overall ceramics market. At present, Spain has over 80 authorized CDW sites. Although these landfill sites are mostly concentrated in certain areas such as Catalonia (55%), Galicia (12%) and Andalusia (11%), the main Spanish cities are considered to have an installation of this type nearby. - Waste management for reuse, recovery and recycling (C3) At present, in Spain there is no specific basic legislation on the production and management of waste produced by construction and demolition (CDW), which is covered by Basic Law 10/1998 on waste. The most usual type of treatment of CDW in Spain is to place it in a landfill site (82.84% according to the latest data available from 2005), and the rest is recycled. This is the scenario applied in this report; 17% of the product is recycled. - Disposal (C4) 83% of the product is sent to a landfill site. 8

9 DAPc Medium porcelain stoneware 2.5. Module D: potential environmental benefits and impacts derived from activities of reuse, recovery and recycling It is considered that impacts are avoided in the manufacture (waste such as cardboard, film, pallets and Big Bag), installation (waste of packaging such as cardboard, plastic and pallets) and end of life of the product. 3. Life cycle assessment The life cycle assessment on which this declaration is based was carried out in keeping with ISO standards and and the document RCP 002 Productos de revestimiento cerámico Version This LCA is cradle to grave that is, it covers the phases of manufacture of the product, construction, use and end of life. Specific data from the Villarreal plant (Castellón) corresponding to the year 2008 has been used to inventory the manufacturing phase. For the rest of the phases, generic data has been used, taken mostly from the official database of the DAPc system and the ELCD database Functional unit The functional unit is 1 m 2 of flooring of a dwelling with stoneware for 50 years of residential use. 9

10 DAPc Medium porcelain stoneware 3.2. Limits of the system A1. Extraction of raw materials MANUFACTURE... Clays, feldespar, kaolin, silicates, additives.etc. Al. Transporte of raw materials A3. Manufacture Storage of raw materials; standardization and handling Cru!hing of atomized granules Manufacture of atomized granules Shaped (pressed) orvfng Milling Spray-drying Glaiing and decoration Finlg Rectification c1a!sification B1. Use BJ. Repair B5. Rehabilitation Card bo ard Packaging! Def locculants and minorrty addrtives Weter Glazes, slip and waler Weter Plastics and palets CONSTRUCTION - A4. Transport A5. Processes of instalation and construction C2. Transport 0. Reuse and recyclin C1. Deconstruction and demolition USE B2. Maintenance B4, Replacement B7. Use of operational wa1er END OF LIFE B6. Use of operational energy C4. Disposal Figure 1. Limits of the system Meterials to be recycled.., ;:; G" e!... C -=., =., c" > 0 c., ~ Meterials to be recycled.. ""0 Meterials to be recycled... Meterials to be recycled...., = J!J <;::.,..,., = ~., E = e s:., = = ~ =., 0 c.. Q COL-LEOI D'APARELLADORS. AROUITECTES TECNICS I ENGtNYERS O'EDIFICACIO OE BARCELONA 10

11 DAPc Medium porcelain stoneware 3.3. Indicators of impact evaluation Table 3. Indicators of impact evaluation Life cycle phase Parameter evaluated Unit per m² of panel Manufactur e Construction Use End of life A1. A3. A4. A5. B1. B2. B3. B4. B5. B6. B7. C1. C2. C3. C4. Potential for global warming kg of CO2 eq. 1.62E E E E E E E-01 Potential for depletion of stratospheric ozone kg of CFC11 eq. 7.37E E E E E E E-09 Potential for acidification kg of SO2 eq. 4.77E E E E E E E-03 Potential for eutrophication kg of PO4 - eq. 4.43E E E E E E E-04 Potential for depletion of abiotic resources kg of Sb eq. 1.09E E E E E E E-03 Potential for the formation of photochemical ozone kg of ethane eq. 4.85E E E E E E E-04 A1. Supply of raw materials B1. Use C1. Deconstruction and demolition -: The PCR do not provide for the calculation of this impact, as it is A2. Transport B2. Maintenance and transport C2. Transport not relevant to this type of product. A3 Manufacture (according to figure 1) B3. Repair C3. Waste management for reuse, recovery A4. Transport B4. Replacement and recycling A5. Processes of installation and construction B5. Rehabilitation C4. Disposal B6. Use of operational energy B7. Use of operational water 11

12 DAPc Medium porcelain stoneware 3.4. Life cycle inventory data (LCI) Table 4. Life cycle inventory data Life cycle phase Parameter evaluated Unit per m² of panel Manufactur e Construction Use End of life A1. A3. A4. A5. B1. B2. B3. B4. B5. B6. B7. C1. C2. C3. C4. Consumption of primary renewable energy MJ (net calorific value) 1.72E E E E E E E-01 Consumption of primary non-renewable energy MJ (net calorific value) 2.51E E E E E E E+00 Use of non-renewable secondary fuels MJ (net calorific value) 0.00E E E E E E E+00 Use of renewable secondary fuels MJ (net calorific value) 0.00E E E E E E E+00 Consumption of fresh water m 8.70E E E E E E E-03 Production of waste kg 8.74E E E E E E E+01 Hazardous kg 1.28E E E E E E E+00 Non-hazardous kg 8.73E E E E E E E+01 Radioactive kg 8.74E E E E E E E+00 Material released for kg 3.00E E E E E E E+00 Reuse kg 0.00E E E E E E E+00 Recycling kg 3.00E E E E E E E+00 Energy recovery kg 0.00E E E E E E E+00 A1. Supply of raw materials B1. Use C1. Deconstruction and demolition -: The PCR do not provide for the calculation of this impact, as it is A2. Transport B2. Maintenance and transport C2. Transport not relevant to this type of product. A3 Manufacture (according to figure 1) B3. Repair C3. Waste management for reuse, recovery A4. Transport B4. Replacement and recycling A5. Processes of installation and construction B5. Rehabilitation C4. Disposal B6. Use of operational energy B7. Use of operational water 12

13 DAPc Medium porcelain stoneware 3.5. Potential environmental benefits and impacts derived from activities of reuse, recovery and recycling Annexe 1 - Table 3. Indicators of impact evaluation Reuse, recovery and recycling Annexe 1 - Table 4. Life cycle inventory data Reuse, recovery and recycling Parameter evaluated Potential for global warming Potential for depletion of stratospheric ozone Unit per m² of panel kg of CO2 eq. kg of CFC11 eq D E E-07 Parameter evaluated Consumption of primary renewable energy Consumption of primary nonrenewable energy Unit per m² of panel MJ (net calorific value) MJ (net calorific value) D E E+01 Potential for acidification kg of SO2 eq E-03 Use of non-renewable secondary fuels MJ (net calorific value) 0.00E+00 Potential for eutrophication kg of PO4- eq E-04 Use of renewable secondary fuels MJ (net calorific value) 0.00E+00 Potential for depletion of abiotic resources kg of Sb eq E-03 Potential for the formation of photochemical ozone kg of ethane eq E-04 D. Potential environmental benefits and impacts derived from activities of reuse, recovery and recycling Consumption of fresh water m 4.01E-03 Production of waste kg -1.37E-04 Hazardous kg -1.86E-07 Non-hazardous kg -4.56E-05 Radioactive Kg -1.96E-09 Material released for kg 0.00E+00 Reuse kg 0.00E+00 Recycling kg 0.00E+00 Energy recovery kg 0.00E+00 D. Potential environmental benefits and impacts derived from activities of reuse, recovery and recycling 3.6. Recommendations of this DAP Construction products should be compared by applying the same functional unit and level of building, i.e. including the product s behaviour throughout its life cycle. Environmental product declarations of different systems of type III eco-labelling are not directly comparable, as the rules of calculation may be different. This declaration represents the average behaviour of the Medium porcelain stoneware product manufactured by Porcelanosa Cut-off rules Over 95% of all the inputs and outputs of mass and energy of the system have been included, excluding, among others, diffuse emissions in the factory. 13

14 DAPc Medium porcelain stoneware 3.8. Other data Waste from the ceramics industry is included as non-hazardous waste in the European Waste Catalogue under EWC code : Waste produced by the manufacture of ceramic products and EWC Waste unspecified in other categories (Decision 2000/532/EC). 4. Technical information and scenarios A) Transport Parameter Consumption of fuel or transport vehicle used Capacity of use (including return full) Density of load of product transported Factor for calculating the capacity of the volume used Parameter expressed by functional unit Transport Spain: 2.51E-04 l/km Transport Europe: 1.80E-04 l/km Transport world: 3.65E-06 l/km 85% for road transport and 100% for freighter 2,250 kg/m for a truck for a freighter 14

15 DAPc Medium porcelain stoneware B) Processes of installation Parameter Auxiliary materials for installation Consumption of other resources Quantitative description of the type of energy and consumption during the process of installing the product Waste on the construction site, generated by the installation of the product Parameter expressed by functional unit Mortar: 3.5 kg kg of water Spain: Cardboard for incineration: Cardboard for recycling: Cardboard to landfill sites: Pallet for incineration: Pallet for recycling: Pallet to landfill sites: Plastic for incineration: Plastic for recycling: Plastic to landfill sites: 3.64E-03 kg 3.83E-02 kg 1.88E-02 kg 9.50E-04 kg 8.90E-04 kg 1.82E-04 kg 1.12E-03 kg 1.60E-03 kg 5.28E-03 kg Europe: Cardboard for incineration: Cardboard for recycling: Cardboard to landfill sites: Pallet for incineration: Pallet for recycling: Pallet to landfill sites: Plastic for incineration: Plastic for recycling: Plastic to landfill sites: 8.71E-03 kg 3.22E-02 kg 1.05E-02 kg 2.90E-04 kg 5.51E-04 kg 6.09E-04 kg 1.49E-03 kg 1.55E-03 kg 2.70E-03 kg Material output as a result of the processes of waste management in the place of installation. For example: collection for recycling, for energy recovery and disposal Emissions to the air, land and water World: Cardboard for incineration: Cardboard for recycling: Cardboard to landfill sites: Pallet for incineration: Pallet for recycling: Pallet to landfill sites: Plastic for incineration: Plastic for recycling: Plastic to landfill sites: 5.54E-03 kg 2.77E-03 kg 1.94E-02 kg 1.85E-04 kg 4.61E-04 kg 2.77E-04 kg 7.30E-04 kg 3.65E-04 kg 2.56E-03 kg See previous point, Waste on the construction site, generated by the installation of the product 15

16 DAPc Medium porcelain stoneware C) Operational use of energy and water Parameter Type of energy, for example: electricity, natural gas, use of heat for a district Outputs Net consumption of fresh water Characteristic representation (energy efficiency, emissions, etc.) Service life (reference) Parameter expressed by functional unit 50 years D) Maintenance and repair Parameter Maintenance, for example; cleaning agent, type of surfactant Maintenance cycle Energy input for the maintenance process Net consumption of fresh water during maintenance or repair Inspection, maintenance or repair process Inspection, maintenance or repair cycle Auxiliary materials, e.g. lubricant Changing of parts during product life cycle Energy input during maintenance, type of energy, e.g.: electricity, and amount Energy input during the process of repair, renovation, changing parts if applicable Loss of material during maintenance or repair Service life of the product for inclusion as a basis to calculate the number of times a change is needed in the building Parameter expressed by functional unit Quantities for cleaning 1 m 2 (once) = kg detergent kg water Cleaning for residential use = once/week* 52 weeks/year* 50 years =2600 washes m 3 50 years 16

17 DAPc Medium porcelain stoneware E) End of life Process Collection processes Recycling systems Disposal Parameter expressed by functional unit of components, products or materials kg collected with construction waste 3.69 kg kg of material for disposal including loss of material 5. Additional information - EC coding - Euroclass of reaction to fire : A1 / A1 fl - BIa group mechanical resistance > 2,000 N / Technical characteristics of > 40 N/mm 2 \\\ BIb group > 1,800 N / > 32 the product N/mm 2 - BIa group water absorption 0.5% \\\ BIb group 0.5% < E 3% Transport and construction - Density of load transported: 2,250 kg/m 3 - Mortar: 1.3 kg - Useful life (years): 50 Use and maintenance - Maintenance and cleaning recommendations: use 0.1 kg water/wash and kg detergent. Frequency of washing indicated is once a week. End of life - EWC code according to European Waste Catalogue (Directive 2000/532/EC): EWC : Waste from the manufacture of ceramic products and EWC Waste not specified in another category Certified by the implementation of a Quality System that meets the requirements of ISO 9001:2000 (attached) Certified by the implementation of an Environmental Management System that meets the requirements of ISO (attached) EC declaration of conformity (Construction Products Directive 89/106/EC) 17

18 DAPc Medium porcelain stoneware 6. PCR and verification This declaration is based on the document RCP 002 Productos de revestimiento cerámico V.1. RCP 002- Productos de revestimiento cerámico V.1 was revised by the Advisory Board of the DAPc system, of which Núria Pedrals is President (Directorate General of Quality in Construction and Housing Rehabilitation - Department of the Environment and Housing - Generalitat de Catalunya) Independent verification of the declaration and data, in accordance with ISO standard 14025:2006 D Internal External Third-party verifier: - Ferran Pérez Ibáñez i CAT Oficina d'acreditaci6 d'entitats Col laboradores Verificaci6 VEDAP ITeC Date of verification: 28 October 2010 References Life Cycle Assessment of Medium Stoneware Products. GiGa (ESCI-UPF) with the collaboration of the Instituto de Tecnología Cerámica (ITC-AICE) for Porcelanosa 2010 (unpublished). COL-LEOI D'APARELLADORS. AROUITECTES TECNICS I ENGtNYERS O'EDIFICACIO OE BARCELONA 18

19 DAPc Medium porcelain stoneware Blank page 19

20 DAPc Medium porcelain stoneware SYSTEM ADMINISTRATOR Col legi d Aparelladors, Arquitectes Tècnics i Enginyers de l Edificació de Barcelona (CAATEEB) Bon Pastor 5, Barcelona. ***** EMAS GESTIO AMBIENTAL VERIFICADA REG. No II IN 1Th1PRl:.SA CERTIFJCADA COL-LEOI D'APARELLADORS. AROUITECTES TECNICS I ENGtNYERS O'EDIFICACIO OE BARCELONA 20

21 DAPc Medium wall tile ENVIRONMENTAL PRODUCT DECLARATION PRODUCT DAPc Medium wall tile COMPANY C---- PRODUCT DESCRIPTION The Medium wall tile product includes various models. PCR REFERENCE RCP 002 Productos de revestimiento cerámico Version 1 (2010) IN ACCORDANCE WITH ISO STANDARDS and PRODUCTION PLANT Carretera N-340, Km 56 Villarreal, Castellón VALIDITY From: To: The validity of DAPc is subject to the conditions of DAPc regulations. The relevant version of this DAPc is included in the register kept by the CAATEEB; for more information, consult the system s website: #~~ COL-LEOI D'APARELLADORS. AROUITECTES TECNICS Y..a, I ENGtNYERS O'EDIFICACIO OE BARCELONA 1

22 DAPc Medium wall tile Blank page 2

23 DAPc Medium wall tile Environmental Product Declaration: Medium wall tile Executive summary DAPc SYSTEM Environmental product declarations in the construction sector SYSTEM ADMINISTRATOR Col legi d Aparelladors, Arquitectes Tècnics i Enginyers d Edificació (CAATEEB) C. Bon Pastor, 5, Barcelona HOLDER OF THE DECLARATION, Carretera N-340, Km 56, Villarreal, Castellón DECLARATION CARRIED OUT BY: GiGa (Escola Superior de Comerç Internacional-Universitat Pompeu Fabra) Calle Pujades 1, 08003, Barcelona - Spain DECLARATION NUMBER DAPc PRODUCT DECLARED Medium wall tile PRODUCT DESCRIPTION The product in question is a medium wall tile that includes different models of wall tile, with a variability of no more than 10% between input and output. REGISTRATION DATE VALIDITY This verified declaration authorizes the holder to use the DAPc eco-label logo. The declaration is applicable exclusively to the product in question and for five years as of the date of registration. Porcelanosa is responsible for the information contained in this declaration. ENDORSED BY THE CAATEEB Rosa Remolà, President of the CAATEEB ~,,,,,,.. COI...L CJI O'APARELLAO RS, ~~ ECTES T~CNICS I ENGINVERS O'EOI r - - SARGlil.QNA ~ / ~ I ENDORSED BY AUTHORIZED VERIFIER Xavier Folch, accredited auditor of the ITEC r 1111 f -- -r- '2--C::: 'lllcnoldgla 119 la can.ucd6 dac:.t.llllljii This environmental product declaration complies with ISO standards and and contains information of an environmental nature about the life cycle of the Medium wall tile product manufactured by Porcelanosa at its plant in Villarreal (Castellón). This declaration is based on the document RCP 002 Productos de revestimiento cerámico Version COL-LEOI D'APARELLADORS. AROUITECTES TECNICS I ENGtNYERS O'EDIFICACIO OE BARCELONA 3

24 DAPc Medium wall tile Environmental Product Declaration for the Medium wall tile 1. Description of the product and its use The product in question is a Medium wall tile that includes different models of stoneware with a variability of no more than 10% between input and output. It includes the following models: Water absorption group BIII (dry pressed with AA > 10%) Commercial name: MONKER MOSAICOS / MONKER REVESTIMIENTO RECTIFICADO / MONKER DECORADOS / MONKER REVESTIMIENTO Nominal formats (cm): 20x31.6x1 / 31.6x44x1.1 / 31.6x59.2x1.1 / 31.6x90x1.2 / 31.6x59.2x0.85 / 31.6x90x0.87 / 45x90x0.87 / 31.6x44x0.85 Average weight: 19.4 kg/m 2 The principal recommended use for this product is as a covering for interior walls. 2. Description of the life cycle phases 2.1. Manufacture (A1, A2 and A3) Raw materials (A1 and A2) The Medium wall tile product basically comprises clay, carbonate, sand and feldspar with an enamel layer mainly comprising feldspar, carbonate, silicate and kaolin, among others. The raw materials used have different origins (provincial, national and United Kingdom). This variation is due to the inability to obtain these materials from a single source. The raw materials from outside Spain are transported by freighter to the port of Castellón and then by truck to the plants. For marine transport, a transoceanic freighter was chosen, with transport distance differing according to the source (United Kingdom). All the raw materials are transported in bulk, i.e., they do not require packaging materials. Manufacture (A3) Once at the factory, the raw materials are transported to the interior of the plant and stored individually in hoppers that dispense the amount of each raw material to start the process. Once the mix has been made, it is subjected to the processes of milling (or grinding) and then spraying. This stage of the production process serves to produce a homogeneous mixture of the various components with a given particle size and prepares it for moulding the tiles. The wet milling is carried out using discontinuous mills (8). The spraying process eliminates excess moisture from the slip. The slip is introduced into the atomizer by sprays that pulverize it and, in contact with a flow 4

25 DAPc Medium wall tile of hot air, it dries, becomes atomized and turns into powder, which falls due to gravity. The atomized powder is stored in silos. The company employs a system of combined heat and power for the atomizer. The cogeneration process generates electricity using residual heat produced by combustion, by means of a system of turbine and alternator. In a cogeneration plant with the use of a fuel such as natural gas, hot air is generated by a burner, and electricity by a turbine. The hot air produced by combustion during cogeneration is used for the spraying process, avoiding the use of the burners. The electricity generated by the turbo-alternator is consumed during the process of manufacturing tiles. The tile is then given the desired form. The flat tiles are moulded in simple dry presses that apply flat unidirectional pressure, applied only on one surface of the tile. When removed from the press, the tiles are partially dried in vertical driers to further reduce moisture content, thereby doubling or tripling their mechanical resistance, prior to subsequent processing. Then the temperature of the tile is reduced to a relatively low temperature and the rough edges are removed (the edges are sanded). Shortly after being removed from the drier, the tiles are given one or several coats of glaze. They are treated in this way to give the surface of the fired product a series of technical and aesthetic properties, such as: Impermeability Ease of cleaning Shine and colour Surface texture Chemical resistance Mechanical resistance The first phase before the application of ceramic glazes is the formulation and preparation thereof. Glazes are manufactured at a plant outside Porcelanosa. On the basis of a given oxide composition, the appropriate raw materials are chosen to produce the chemical composition and mineralogical structure that produce the final properties. They principally comprise silica and quartz, followed by oxidizing agents, alkalis, carbonates and zinc oxides (to give particular characteristics of opacity and shine to the frit). These raw materials are mixed and wet milled to produce a slip similar to the one prepared for the tile itself, but with a smaller particle size and a higher percentage of water. The glazing operation involves the successive application of enamel suspension. The glazing line consists of a system of belts driven by pulleys, onto which the ceramic tiles are automatically placed as they emerge from the dryer. Organized along this belt is the necessary equipment to apply the slip and the glaze, both in the form of slurry on the tile support, using a continuous glazing compartment. Then the desired decoration is applied. In this phase, the patterns and designs are applied to the tiles, which are stored in a warehouse before they are put into the kilns. 5

26 DAPc Medium wall tile The firing is the most important stage of the production process of ceramic tiles, as this is when the previously moulded tiles undergo a fundamental modification of their properties. The tiles are unloaded from the wagons onto a conveyor belt, forming continuous expanses in the monolayer roller kiln. Once fired, the tiles are transported to the classification station, where an aesthetic (visual) and dimensional examination is carried out. The dimensional examination consists of determining deviations in length and width, orthogonality, straightness of sides and flatness of surface by means of an optical measurement system. The tiles are then packaged. Some series of tiles are taken away to be rectified by grinding, thereby ensuring perfect edges before they are classified and packaged. The tiles that meet standards (or have been rectified) are packaged using cardboard, pallets and polyethylene. Once the pallet is made up, it is stored in the logistics area of the plant. To reduce atmospheric emissions, bag filters are used, comprising a textile membrane that is permeable to gases but retains the dust in. The tile factory has a closed system of water reuse. Water may be lost by evaporation or by being retained in the product (before ultimately evaporating). To make up for this loss, well water is brought in for the production process. The water is treated using a physical-chemical process and is reintroduced in the atomization processes Construction Transport of the product (A4) Porcelanosa produces tiles that are commercialized both nationally (46%) and in Europe (33%) and the rest of the world (21%). The most frequent destinations are: National: Madrid, Barcelona, Valencia, Seville, Saragossa, Málaga, Bilbao and Castellón (province) Europe: France, Great Britain, Italy and Eastern European countries Rest of the world: USA, Australia, Japan, China and South America (Argentina) In keeping with the data provided by Porcelanosa, there are three transport scenarios for the finished products. 6

27 DAPc Medium wall tile Table 1. Scenarios for transport of the product to the place of installation Destination Type of transport Percentage (%) Spain 27 t truck 46 Europe 27 t truck 33 Rest of the world Transoceanic freighter 21 Total 100 For transcontinental transport, medium-sized transoceanic freighters are considered appropriate. All the models used are included in the database [GaBi 4.3]. The estimated distances between the tile factories and the place of installation are: km and 2,000 km for products installed in Spain and Europe, respectively. - 5,000 km for products transported to and installed in the rest of the world Process of installing the product and construction (A5) Once the product is unpacked, it can be installed. According to the data obtained and with a view to applying a real scenario, it is established that installation calls for the use of quick-setting mortar (CaSO4). Tile adhesives are cement-based adhesives comprising a mixture of hydraulic binders, mineral fillers and organic additives, mixed with water or added liquid just before use. They consist of a mixture of white or grey cement, siliceous mineral fillers and/or limestone and organic additives, water retainers, water redispersible polymers, rheology modifiers, fibres, etc Use of the product The use phase is divided into the following modules: Use (B1) Maintenance (B2) Repair (B3) Replacement (B4) Rehabilitation (B5) Use of operational energy (B6) Use of operational water (B7) Once installed, the medium stoneware product requires no further energy input for use, nor does it call for maintenance, except normal cleaning operations. For this reason, of all the modules listed above, only the environmental impacts attributable to product maintenance are applicable (module B2). 7

28 DAPc Medium wall tile According to Porcelanosa, the useful life of the product is the same as that of the building in which it is used; provided it is correctly installed, it is a lasting product. - Maintenance (B2) The product should be cleaned with a damp cloth. If the surface is dirty or greasy, cleaning agents such as detergents or bleach may be added. This study considers the consumption of water and disinfectant for a scenario of residential use. Scenario 1: residential use 0.03 kg of detergent and 5 l of water are used to wash 50 m 2 of floor tiles, once a week. Table 2. Scenarios for the maintenance of 1 m 2 of Medium wall tile product Cleaning products Scenario 1 Water (kg/wash) 0.1 Detergent (kg/wash) Frequency of washing (num. of times) End of life The end-of-life phase includes the following modules: - Deconstruction and demolition (C1) Once it reaches the end of its useful life, the product will be removed, either in the framework of rehabilitation of the building or during its demolition. In the case of the demolition of a building, the impacts attributable to the removal of the product are negligible. - Transport (C2) The product waste is transported by truck in compliance with Euro III norms, to its destination at a distance of 50 km. In this estimation of the 50 km between the demolished building and the closest landfill site, only the Spanish market has been taken into account, extrapolating the results to the overall ceramics market. At present, Spain has over 80 authorized CDW sites. Although these landfill sites are mostly concentrated in certain areas such as Catalonia (55%), Galicia (12%) and Andalusia (11%), the main Spanish cities are considered to have an installation of this type nearby. - Waste management for reuse, recovery and recycling (C3) At present, in Spain there is no specific basic legislation on the production and management of waste produced by construction and demolition (CDW), which is covered by Basic Law 10/1998 on waste. The most usual type of treatment of CDW in Spain is to place it in a landfill site (82.84% according to the latest data available from 2005), and the rest is recycled. This is the scenario applied in this report; 17% of the product is recycled. - Disposal (C4) 83% of the product is sent to a landfill site. 8

29 DAPc Medium wall tile 2.5. Module D: potential environmental benefits and impacts derived from activities of reuse, recovery and recycling It is considered that impacts are avoided in the manufacture (waste such as cardboard, film, pallets and Big Bag), installation (waste of packaging such as cardboard, plastic and pallets) and end of life of the product. 3. Life cycle assessment The life cycle assessment on which this declaration is based was carried out in keeping with ISO standards and and the document RCP 002 Productos de revestimiento cerámico Version This LCA is cradle to grave that is, it covers the phases of manufacture of the product, construction, use and end of life. Specific data from the Villarreal plant (Castellón) corresponding to the year 2008 has been used to inventory the manufacturing phase. For the rest of the phases, generic data has been used, taken mostly from the official database of the DAPc system and the ELCD database Functional unit The functional unit is 1 m 2 of cladding of a dwelling with tiles for 50 years of residential use. 9

30 DAPc Medium wall tile 3.2. Limits of the system MANUFACTURE A1. Extraction of raw materials Clays, feldespar, kaolin, silicates, additives.etc. Kl.. Transporte of raw materials A3. Manufacture Storage of raw materials; standardization and handling Crushing of atomized granules Manufacture of atomized granules Sh1ped (pressed) oring Milling Spray-drying Gla1ing and decoration Firi1g Re~ificalion Dry+g Classificati on 81. Use 83. Repair A4. Transport... Cardboa rd Packaging ~ CONSTRUCTION USE Deflocculants and minorrty addrtives Water Glazes, slip and water J Materials for r,eparation of glazes and slips -Water Water Plastics and pallets A5. Processes of instalation and construction 82. Maintenance 84. Replacement 85. Rehabilitation 86. Use of operational energy Materials to be recycled c,. u C i:i' e! -= C (<, c".. ~.. u ~ ~ ~ ~ - s 'fl (<, E 0 -::: -=.. -~.. -= Materials ~ lo be [ rec:ycled.,:s C (<,,iii t;::: C.. Materials to be rec:ycled... -= -;;; =.. E C e s C Use of operational water C2. Transport CJ. Reuse and recyclin C1. Deconstruction and demolition END OF LIFE C4. Disposal Figure 1. Limits of the system Materials to be rec:ycled... COL-LEOI D'APARELLADORS. AROUITECTES TECNICS I ENGtNYERS O'EDIFICACIO OE BARCELONA 10

31 DAPc Medium wall tile 3.3. Indicators of impact evaluation Table 3. Indicators of impact evaluation Life cycle phase Parameter evaluated Unit per m² of panel Manufactur e Construction Use End of life A1. A3. A4. A5. B1. B2. B3. B4. B5. B6. B7. C1. C2. C3. C4. Potential for global warming kg of CO2 eq. 1.81E E E E E E E-01 Potential for depletion of stratospheric ozone kg of CFC11 eq. 5.56E E E E E E E-09 Potential for acidification kg of SO2 eq. 4.46E E E E E E-03 Potential for eutrophication kg of PO4 - eq. 4.37E E E E E E E-04 Potential for depletion of abiotic resources kg of Sb eq. 1.19E E E E E E E-03 Potential for the formation of photochemical ozone kg of ethane eq. 4.93E E E E E E E-04 A1. Supply of raw materials B1. Use C1. Deconstruction and demolition -: The PCR do not provide for the calculation of this impact, as it is A2. Transport B2. Maintenance and transport C2. Transport not relevant to this type of product. A3 Manufacture (according to figure 1) B3. Repair C3. Waste management for reuse, recovery A4. Transport B4. Replacement and recycling A5. Processes of installation and construction B5. Rehabilitation C4. Disposal B6. Use of operational energy B7. Use of operational water 11

32 DAPc Medium wall tile 3.4. Life cycle inventory data (LCI) Table 4. Life cycle inventory data Life cycle phase Parameter evaluated Unit per m² of panel Manufactur e Construction Use End of life A1. A3. A4. A5. B1. B2. B3. B4. B5. B6. B7. C1. C2. C3. C4. Consumption of primary renewable energy MJ (net calorific value) 1.35E E E E E E E-01 Consumption of primary non-renewable energy MJ (net calorific value) 2.67E E E E E E E+00 Use of non-renewable secondary fuels MJ (net calorific value) 0.00E E E E E E E+00 Use of renewable secondary fuels MJ (net calorific value) 0.00E E E E E E E+00 Consumption of fresh water m 5.05E E E E E E E-03 Production of waste kg 9.96E E E E E E E+01 Hazardous kg 1.21E E E E E E E+00 Non-hazardous kg 9.95E E E E E E E+01 Radioactive kg 6.88E E E E E E E+00 Material released for kg 3.08E E E E E E E+00 Reuse kg 0.00E E E E E E E+00 Recycling kg 3.08E E E E E E E+00 Energy recovery kg 0.00E E E E E E E+00 A1. Supply of raw materials B1. Use C1. Deconstruction and demolition -: The PCR do not provide for the calculation of this impact, as it is A2. Transport B2. Maintenance and transport C2. Transport not relevant to this type of product. A3 Manufacture (according to figure 1) B3. Repair C3. Waste management for reuse, recovery A4. Transport B4. Replacement and recycling A5. Processes of installation and construction B5. Rehabilitation C4. Disposal B6. Use of operational energy B7. Use of operational water 12

33 DAPc Medium wall tile 3.5. Potential environmental benefits and impacts derived from activities of reuse, recovery and recycling Annexe 1 - Table 3. Indicators of impact evaluation Reuse, recovery and recycling Annexe 1 - Table 4. Life cycle inventory data Reuse, recovery and recycling Parameter evaluated Potential for global warming Potential for depletion of stratospheric ozone Unit per m² of panel kg of CO2 eq. kg of CFC11 eq D E E-07 Parameter evaluated Consumption of primary renewable energy Consumption of primary nonrenewable energy Unit per m² of panel MJ (net calorific value) MJ (net calorific value) D E E+01 Potential for acidification kg of SO2 eq E-03 Use of non-renewable secondary fuels MJ (net calorific value) 0.00E+00 Potential for eutrophication kg of PO4- eq E-04 Use of renewable secondary fuels MJ (net calorific value) 0.00E+00 Potential for depletion of abiotic resources kg of Sb eq E-03 Potential for the formation of photochemical ozone kg of ethane eq E-04 D. Potential environmental benefits and impacts derived from activities of reuse, recovery and recycling Consumption of fresh water m 3.41E-03 Production of waste kg -1.33E-04 Hazardous Kg -1.82E-07 Non-hazardous kg -1.34E-04 Radioactive kg -1.92E-09 Material released for kg 0.00E+00 Reuse kg 0.00E+00 Recycling kg 0.00E+00 Energy recovery kg 0.00E+00 D. Potential environmental benefits and impacts derived from activities of reuse, recovery and recycling 3.6. Recommendations of this DAP Construction products should be compared by applying the same functional unit and level of building, i.e. including the product s behaviour throughout its life cycle. Environmental product declarations of different systems of type III eco-labelling are not directly comparable, as the rules of calculation may be different. This declaration represents the average behaviour of the Medium wall tile product manufactured by Porcelanosa Cut-off rules Over 95% of all the inputs and outputs of mass and energy of the system have been included, excluding, among others, diffuse emissions in the factory. 13