Sustainability Performance Report 2nd report: 2012 performance data

Transcription

1 Sustainability Performance Report 2nd report: 2012 performance data Managing Directors Statement In 2012 Lignacite Ltd committed to a Sustainable Strategy for Masonry. This initiative has been the catalyst to enable us to respond to the construction industries need for industry-wide reporting and delivering our ambition of continuous improvement. We are now publishing this second performance report to stakeholders. This report provides company data for a range of key indicators, set against a benchmark of previous performance and a 2013 target. Communicating and informing our colleagues and customers is also a key strategic objective for our strategy. As the UK construction industry s approach to sustainability develops it is essential that our own Strategy keeps apace. During 2013 we intend to review and publish our Sustainable Strategy for Masonry, ensuring it is fit for purpose in meeting company and stakeholder requirements. Sustainable products, such as those containing coloured glass aggregate supplied to Blackpool Tower, help to deliver on client expectations GAJ de Lotbiniere Managing Director Key Highlights In 2012, the production of a standardised tonne of Lignacite concrete produced 8.40kg/C02 In 2012 certification was achieved to BES Framework Standard for the Responsible Sourcing of Construction Products Nine of the 12 targets set for 2012 have been met or exceeded. Considerable work has been done on the carbon foot printing of the product range to the extent that carbon values can be reliably quoted. Lignacite Sustainability Performance Report for 2012 Page 1

2 Introduction Concrete masonry blocks are the most widely used walling material and is a fundamental part of our sustainable built environment; essential for the construction of our housing, schools, hospitals and transport networks. Since 2008, when the majority of the UK concrete industry committed to the Concrete Industry Sustainable Construction Strategy, construction activity and the use of building materials has declined significantly due to the recession. Despite the economic downturn our sustainability initiatives continues to grow. This is not by accident but by a need to move the business forward on the back of strong sustainability credentials that meet or exceed the expectations of our stakeholders. The report presents a range of performance indicators that represent the most significant sustainability topics and support the Government Strategy for Sustainable Construction [1]. Lignacite Ltd is largely covered by certified management systems such as ISO 9001 and ISO Lately our approach to responsible souring has been examined by BSI and following a rigorous assessment, certification to BES Framework Standard for the Responsible Sourcing of Construction Products was achieved. This approach to the third party assessment of our management systems is welcomed and provides a strong platform for continuous improvement and delivery of sustainable masonry products. 12 performance indicators with targets for improvement were set for Of these, 9 targets were met or exceeded. Go to the final page of this Report for a summary of our verified sustainability performance for Looking forward Lignacite Ltd is committed to an update of its Sustainable Strategy for Masonry. This forward thinking initiative is published on our web site and is consistent with the Concrete Industry Sustainable Construction Strategy. This provides the roadmap for our continual improvement and is indicative of our commitment to a sustainable built environment. Our 2012 Strategy is outlined below. Vision It is our vision for Lignacite Ltd to be recognised as a leader in the masonry sector, in delivering sustainable solutions and by taking a dynamic role in delivering a sustainable, zero carbon built environment in a socially, environmentally and economically responsible manner. Strategic objectives 1. To continue to bring to the market innovative masonry products which satisfy customer requirements, focusing on the visual appeal and performance of masonry. 2. To increase the use of recycled and secondary materials as an alternative to primary materials in its products. This will be achieved by further investment in research and development and a strong commitment to its supply chain to bring such products to the market. 3. To develop masonry solutions which meet technical requirements and are manufactured based on responsible sourcing principles in accordance with BES 6001, thereby enabling its clients to achieve sustainable construction. 4. Communicate our progress and solutions. Commitments 1. To launch an annual Sustainability Performance Report for Lignacite s stakeholders commencing in To set targets for Performance Indicators by To provide clients with industry data for product environmental performance, e.g., LCA (life cycle analysis) models. 4. To develop sustainable masonry solutions. 5. To achieve external certification of the responsible Sourcing principles operated by Lignacite in accordance with BES 6001 Lignacite Sustainability Performance Report for 2012 Page 2

3 Sustainable Consumption and Production Environmental Management Compliance with a UKAS certified EMS Environmental Management Systems (EMS) provide the framework for a sustainability strategy and are a key element in gaining certification to the BES responsible sourcing standard. Improvement plans form part of the EMS and help to drive improvements Framework Standard for the Responsible Sourcing of Construction Products was achieved. This approach to the third party assessment of our management systems is welcomed and provides a strong platform for continuous improvement and delivery of sustainable masonry products. Our objective is to maintain a certified EMS. This we have achieved for Quality and Performance Compliance with a UKAS certified ISO 9001 QMS Certified Quality Management Systems (QMS) are the basis for delivering product consistency and performance as well as providing supply chain engagement. Certification through BSI, has been a consistent feature of our product quality since the 1980s. The relative performance of BES 6001 compared to other schemes is now recognized in BREEAM 2011[2. Designers can now specify Lignacite s products knowing that credits can be obtained under environmental schemes such as BEREEAM and the Code for Sustainable Homes. New logo for BES 6001 certifcation The increasing importance of BES 6001 in supporting sustainable construction has resulted in BRE has resulted in BRE launching a logo to easily identify products which meet the demanding requirements of the standard. Lignacite is proud to apply this logo to its product range and by doing so this will help many projects to meet their % target of materials for construction projects to be responsibly sourced. Our objective is to maintain a certified QMS. This we have achieved for Responsible Sourcing Over the last year Lignacite Ltd has taken significant steps to demonstrate its responsible sourcing credentials by gaining third party certification to BES Having achieved certification, we are already looking to improve our rating under BES 6001 and it is a key objective that we achieve this during Concrete blocks are generally a locally sourced material so its constituents are both traceable and subject to the comprehensive EU regulatory framework. Lignacite Sustainability Performance Report for 2012 Page 3

4 Sustainable Consumption and Production Emissions (excluding CO2) Number of convictions per annum for air and water emissions A zero target has been set for the Number of convictions per annum for air and water emissions. To do otherwise would mean that we expect to have an incident with unspecified consequences. The drive to deliver on this objective is primarily through our BSI certified EMS. In 2012 a zero target was achieved and we strive for a similar outcome in engagement we aspire to. A key objective for 2012 was to publish our Sustainable Masonry Strategy. This was achieved and is available to view on our web site. During 2013 we intend to introduce measures to include improved engagement with the local community in which our manufacturing operations are located. Energy Efficiency Energy used in production as a proportion of production output Stakeholder Engagement There is a wide range of stakeholder activity, predominantly with the supply chain through contact with suppliers, with customers and with specifiers of our products. Specifier and end-user contact is particularly important for the business as it provides a significant amount of feedback, not only on sustainably specific issues but also as a driver for product development. Significant development in the Company s web site was undertaken during A refreshed company image was launched together with improved presentation to the site and a strong emphasis on sustainability related data and topics. This coupled with our face to face contact with clients is intended to improve the level of stakeholder In 2012, the production of a standardised tonne of Lignacite concrete consumed 23.8kWh. Our 2012 target was to reduce energy used in production by 1% and this was achieved. Improving the energy efficiency of our manufacturing process makes business and sustainability sense as well as reducing the embodied energy of our products. When products are used in the context of a building, the primary consideration is its life cycle energy demand. Although our products contribute to the embodied energy of a building, they can play a significant role in minimising operational energy efficiency during its lifetime. The consumption of a largely fixed energy use against a lower output of product can cause fluctuations in this indicator. The cement component remains a major component of the embodied energy in concrete blocks. Concrete block production uses semi-dry mixes which usually require significantly less cement per tonne than wet cast mixes, meaning that the effect of the embodied energy from cement is reduced. Further improvements results from use of cement substitutes Lignacite Sustainability Performance Report for 2012 Page 4

5 Sustainable Consumption and Production such as Betacarb, which is used in a number of our products. Operational energy As well as minimising the embodied contribution of our products, it is their performance over the full life cycle of building which will determine the sustainability of the built environment for future generations. The use of passive design to maximise the inherent thermal mass properties of concrete blockwork can provide considerable energy savings in terms of reduced heating and cooling requirements over the lifetime of a building. Thermal mass relates to the ability of construction materials to absorb heat on hot days to help prevent overheating problems, without recourse to energy dependent cooling. Night time ventilation removes the stored heat. During the winter, the absorbed heat provides a buffer within the building to help maintain a constant ambient temperature without using additional energy. Planned changes to Part L thermal standards with require increasing amounts of insulation to be installed to all new building types. It is therefore likely that the risk of overheating in buildings will increase and the need to consider heat cooling materials such as Lignacite s concrete masonry will be of increasing benefit. CO2 Emissions Production CO2 emissions Production (Standardised mix) Using a standardised concrete mix, the CO2 emissions for 2012 have been recorded at 8.40kg/CO2/tonne. Our 2012 target was to decrease CO2 emissions by 1% and this has been achieved. Given fluctuations in block sales, and more importantly product mix, a yearly target is not a strong indicator of actual performance. It is proposed to set reduction targets over a longer period whereby production improvements can be properly assessed. We remain committed to reducing CO2 emissions by investment in plant, process and the people involved in the production of our masonry blocks. CO2 Emissions Transport CO2 emissions of total product delivery transport Lignacite s high density facing masonry can be used to help control internal heat gains in buildings. The average GHG emission per m2 of product delivered is 769 g/ CO2. Our target is to decrease emissions associated with delivery of our product by 5% against this measure by 2016 using 2012 as a baseline for improvment. A plan has been implemented to achieve this objective and includes replacement delivery vehicles with new vehicles meeting Code 5 Diesel Emissions. The indicator is based on delivered product to customers. Deliveries of constituent materials are not included at present. Lignacite Sustainability Performance Report for 2012 Page 5

6 Natural Resource Protection The majority of our products (and constituent materials) are transported by road. Efficiencies are supported by working practices which include route planning, maximising pay load wherever possible, and optimising pack sizes. Deliveries are undertaken by owner drivers and subcontract vehicles. Materials Efficiency Recycled/secondary aggregates The use of recycled/secondary aggregates as a proportion of total aggregates used Waste Minimisation Waste to landfill as a proportion of production output All of Lignacite s production waste is processed back into the product, therefore no production scrap is diverted to landfill. Our target is and will continue to be 0% of production waste to landfill. From production data, approximately 11.3kg/tonne of production waste was reused back into the product. Water Mains water consumption as a proportion of production output Our target for 2012 was to use a minimum of 26% by volume of recycled material. A usage of 27% has been recorded, thereby satisfying our objective to use increasing amounts of recycled material To reduce our demands for primary materials, as well as recycling our own process waste, we are very active in the use of by-products, secondary materials and material diverted from the waste stream. Use of alternative raw materials has been a key feature of products since the inclusion of graded wood particles in the first Lignacite blocks produced in The use of recycled materials is an important aspect of product design and manufacture. The sustainable outcome of including larger volumes of recycle secondary materials into concrete manufacture is very dependent upon the availability of such material of the right quality and in a sustainable quantity. In precast concrete manufacture the use of recycled aggregates is around 25% of the proportion of total aggregates used. Our actual consumption and future targets surpass this figure by a significant margin. Block production utilises semi-dry mixes saving considerable water compared to normal cast concrete. Our target for 2012 was to maintain water usage at 48.9 litres/tonne of product. This target was achieved, thereby satisfying our objectives to maintain water usage at this consumption rate. A key feature of concrete block manufacture is the use of semi-dry mixes that are compacted and vibrated using powerful block machinery. This is necessary for the immediate demoulding of the product. A benefit of this production method is the use of very little water per tonne, compared to ready mix concrete. Typically ready mix concrete will use 60 to 80 litres of water per tonne compared to around 45 litres of water per tonne for Lignacite Lignacite Sustainability Performance Report for 2012 Page 6

7 Creating Sustainable Communities production. We recognise that there is very little opportunity to reduce this figure further and consequently our efforts are focused on maintaining this level of water use through our 9001 Quality System. We also have in place a project to investigate rainwater capture from buildings and the like for reuse into production. Health and Safety Reportable injuries per total number of employees per annum hours/ employee was recorded in 2012 but no target was set. A target will be introduced for Local Community During 2012 a local community newspaper was compiled and this was finalized and issued to neighbours in the Spring of The newsletter provides information about our operations and how we strive to be a good neighbour, including the employment of local people. It is intended to publish similar newsletters on an annual basis. A feedback form is included so that we can answer any concerns or questions. References The Health and Safety of our employees and those that visit our sites is a top priority. Our target for 2013 is to have no reportable injuries, that is, injuries which result in Lost Time from work. During 2012 one Lost Time Incident occurred. This involved one employee and the incident was fully investigated. Our Health and Safety objectives and targets are consistent with the overall concrete industry, where the ultimate objective is for Zero Harm. Employment and Skills We are committed to a fully trained competent workforce. All production operatives are covered by UKAS certified training and evaluation processes. On the job training is supported by tool box talks and specific training where this is a company or legal requirement. Training hours are recorded and dived by the number of employees to arrive at an average training hours per employee. An average of 14.3 Lignacite Sustainability Performance Report for 2012 Page 7

8 Verification of Performance data Verification Findings for Lignacite s Major Plant at Brandon A key improvement initiative for 2013, was to obtain external verification of data used to set objectives and targets for 2013 and beyond. Independent Data Verification has been achieved through NR Richards Associates Limited, a respected construction focused organization in the field of environmental and sustainability performance. The performance data that has been reviewed and verified is shown in the table below. Aspect Units of Measure Unverified Company Data for Year 2012 Verified Company Data for Year 2012 Energy Use kwh/tonne of production * Energy Use kwh / m 2 of production Energy Use Total kwh / year 2,702,789 2,698,781* Carbon dioxide Kg/tonne of production * emissions Carbon dioxide emissions Kg / m 2 of production Carbon dioxide Total kg CO2 / year 953, ,366* emissions Mains water usage Litres / tonne of production Mains water usage Litres / m 2 of production Non-mains water Litres / tonne of production (borehole) Non-mains water (borehole) Litres / m 2 of production Total water (mains & Litres / tonne of production non-mains) Total water (mains & Litres / m 2 of production non-mains) Own Waste recycled on site Kg/tonne of production Own Waste recycled Kg / m 2 of production on site Transport (excluding Average tonne / delivery collections) Transport (excluding collections) Average delivery distance (km) Training and Hours / employee / year development Local Community Number and type of contacts Various initiatives Various initiatives Relations Local Community Number and type of complaints 0 0 Complaints Note: * indicates that the data has changed as a result the verification audit Lignacite Sustainability Performance Report for 2012 Page 8

9 Lignacite Ltd High Street Brandon Sufolk IP27 0AX Tel: Lignacite Sustainability Performance Report for 2012 Page 9