ENVIRONMENTAL PRODUCT DECLARATION UAC Berhad

ENVIRONMENTAL PRODUCT DECLARATION
as per ISO 14025 and EN 15804
Owner of the Declaration
UAC Berhad
Programme holder
Institut Bauen und Umwelt e.V. (IBU)
Publisher
Institut Bauen und Umwelt e.V. (IBU)
Declaration number
EPD-UAC-20130008-IAC1-EN
Issue date
29/05/2013
Valid to
28/05/2018
UAC Fibre Cement Board
UAC Berhad
www.bau-umwelt.com / https://epd-online.com
Umwelt Produktdeklaration Name des Herstellers – Name des Produkts
1. General Information
UAC Berhad
UAC Fibre Cement Board
Programme holder
IBU - Institut Bauen und Umwelt e.V.
Rheinufer 108
D-53639 Königswinter
Owner of the Declaration
UAC Berhad
Jalan Portland, Tasek Industrieal Estate, 36
31400 Ipoh, Perak
Malaysia
Declaration number
EPD-UAC-20130008-IAC1-EN
Declared product / Declared unit
Per tonne of UAC Fibre Cement Board
This Declaration is based on the Product
Category Rules:
Fibre cement / Fibre concrete, 07-2012
(PCR tested and approved by the independent expert
committee)
Scope:
Issue date
29/05/2013
Valid to
28/05/2018
This EPD declaration is based on average UAC Fibre
Cement Board manufactured by UAC Berhad. These
products are produced in the manufacturing plant
located in Ipoh, Perak in which the production data for
2011 was recorded. Life Cycle Assessment (LCA) was
conducted based on the cradle-to-gate approach
(Modules A1-A3), where the entire production phase of
the UAC Fibre Cement Board was considered in this
LCA study. The Declaration holder is liable for the
details and documentation upon which the evaluation
is based. The owner of the declaration shall be liable
for the underlying information and evidence; the IBU
shall not be liable with respect to manufacturer
information, life cycle assessment data and evidences.
Verification
The CEN Norm EN 15804 serves as the core PCR
Independent verification of the declaration and data
according to ISO 14025
internally
x externally
Prof. Dr.-Ing. Horst J. Bossenmayer
(President of Institut Bauen und Umwelt e.V.)
Patricia Wolf
(Independent tester appointed by SVA)
Prof. Dr.-Ing. Hans-Wolf Reinhardt
(Chairman of SVA)
2. Product
2.1
Product description
The UAC Fibre Cement Boards are 100% abestos free
in composition. These autoclaved composite materials
are made from specially treated high grade cellulose
fibre, Portland cement, refined sand and water.
The declared products include:
- UCO Superflex
- UCO Decoceil/Ucoceil
- UCO Vistaboard/Flexaboard/Multiflex
- UCO Lattices
- UCO Sedartex Woodgrain Plank/Panel
- UCO Supertex Woodgrain Panel/Plank
- UCO Smooth Plank
- UCO Duravent
- UCO Shingles
- UCO Bargeboard
All the declared products are produced at the same
process flow with same raw material composition with
difference of formulation (see 2.6) and geometrical
output.
2
2.2
Application
UAC Berhad manufactures a wide range of Fibre
Cement Boards which are extensively used in
residential, institutional, commercial and industrial
buildings, as:
- Fascia / Siding
- Internal Lining and Wall Partitioning
- Ceiling
- Soffit and Eave Lining
- Substrate for flooring
- Fire and insulation application
- Decorative and innovative application
- Roofing
2.3
Technical Data
UAC Fibre Cement Boards conform and certify to (a)
MS1296:2010 for UCO Superflex and (b)
EN12467:2004 for 7.5mm UCO Sedartex Woodgrain
Plank.
Product specification
UAC Fibre Cement Board (6mm thickness)
- Thermal conductivity (W/mK): 0.12
- Resistance of heat transmission, Ra (m2K / W): 0.19
- Dry density (kg/m3): 1350 to 1450
Environmental Product Declaration UAC Berhad – UAC Fibre Cement Board
Sound proof:
With a 6mm fibre cement sheet (1190mmx1190mm)
installed in the opening between two adjacent but
acoustically isolated reverberation rooms, 17-33dB
sound transmission loss at frequency from 1255000Hz. Airborne noise insulation is determined as
STC30 (tested in accordance to ASTM E90-09).
2.7
Manufacture
Process flow of UCO Fibre Cement Board production:
The difference between the sound absorption of the
room with and without the 6mm fibre cement sheet is
determine to obtain the total sound loss by using the
reverberation time values. Noise reduction coefficient
is determined as NRC0.10 (ASTM E423-90a).
Sound transmission loss (UCO Vistabord): Estimated
25dB (6mm), 28dB (9mm).
2.4
Placing on the market / Application rules
Product standard / approval:
- Malaysia Standard MS 1296: 2010 Fibre cement flat
sheets [for UCO Superflex]
- European Standard EN 12467:2004 Fibre cement flat
sheets – product specification and test methods [for
7.5mm UCO Sedertex Woodgrain Plank].
Under MS1296: 2010:
- Saturated flexural Strength > 10MPa
- Equilibrium moisture content at 23°C, 80% humidity:
6-8%
- Moisture movement (from dry to wet condition) : 0.100.20%
- Passed the requirements of warm water test.
2.5
Delivery status
UAC Fibre Cement Boards are manufactured in a
range of thicknesses from 3.2mm to 15.0mm. The
boards can be up to 3660mm in length and up to
1220mm wide.
2.6
Base materials / Ancillary materials
Value
A uniform film is formed onto the sieves and the film
will be picked up by felt which will then be transferred
to a size roller to be rolled in layers for the
manufacturing of `green sheet` (intermediate product
formed during the production and yet to send to
autoclave) according to the desired thicknesses. The
speed of the felt is controlled in order to achieve
consistent sheet thickness at a specified production
rate.
Individual size roller determines the length of sheet
being produced. If patterned sheet is to be produced, a
patterned sleeve will be placed on the size roller to
create the desired patterns.
Once the desired thickness is achieved, it will then be
separated and taken off from size roller by a cut-off
wire.
The base materials, auxiliary substances and
addictives for UAC Fibre Cement Boards are:
Name
UAC Fibre Cement Boards are produced with
Hatschek process or wet process:
The raw materials are mixed homogeneously and
pumped to the tubs at controlled rate so that tubs are
filled and overflow.
Unit
% of dry
Base Material: Cement
30 – 40
mass
% of dry
Base Material: Silica
50 – 60
mass
% of dry
Base Material: Pulp / cellulose fibre
6–9
mass
Auxiliary Substances / Additives:
% of dry
0–5
Alumina / Alumina Tri-hydrate
mass
Auxiliary Substances / Additives: Silica
% of dry
0–5
Fume
mass
Auxiliary Substances / Additives: Red
% of dry
0–1
Pigment
mass
The green sheet will then be trimmed into size by high
pressure water jet while the remaining scraps will
return to scrap agitator which will then transferred back
to feed agitator for reuse in order to minimise waste
generated.
The trimmed green sheets are stacked in tiers on steel
base pallet.
The stacked green sheets will then be air-cured for
minimum 6-8 hours before curing in autoclave for a
total process duration of 10-12 hours.
The autoclaved sheets will undergo further cutting or
trimming into the final dimension at sheet finishing with
either guillotine knife or rotating saw. Sanding, edge
recessing and slotting are also being done at sheet
finishing.
Quality Management System in accordance to ISO
9001:2008 for design and manufacture of fibre cement
products.
2.8
Environment and health during
manufacturing
The UAC Berhad operation is compliances with
OHSAS 18001:2007 (Occupational health and safety
3
Environmental Product Declaration UAC Berhad – UAC Fibre Cement Board
management).
Water: Water contamination was not reported during
the production of UAC Fibre Cement Boards. All the
waste water is treated at a designated waste water
treatment plant before discharging into the
environment, in accordance to the Environmental
Quality Act 1974 /Act 127/.
Noise: Sound protection analyses and close
monitoring on exposure limits have been established in
accordance to Factory and Machineries Act (Noise
Exposure) Regulations 1989 /Act139/.
Waste:
All scraps and rejected UAC Fibre Cement Boards are
classified as solid waste under the Malaysia
Department of Environment (DOE) Regulations and
will be treated in landfill /Act672/.
2.9
Product processing/Installation
UAC Fibre Cement Boards are cut using guillotine
knife or circular saw with tungsten carbide, and
diamond saw blade. Dust generated from the
processes is collected through the effective dust
collecting system and filtered before release to air in
accordance to Factories and Machinery Act (Mineral
Dust) Regulations 1989 /Act 139/. Dust emission is
below the Permissible Level under Regulation 25 of
the Malaysia Environmental Quality (Clean Air)
Regulations 1978 /Act 127/.
2.10 Packaging
UAC Fibre Cement Boards are packed horizontally on
wooden pallets and packaged with polyethylene
stretch film, PET strap and cardboard edge protector.
The wooden pallets are reused internally.
2.11 Condition of use
UAC Fibre Cement Boards have passed organic
emissions tests under the TUV Singapore emission
standards for formaldehyde, phenylcyclohexene,
phthalate, and total particle. Due to stable crystalline
calcium silicate hydrate phase after the autoclave
process, the emission of volatile organic compound
(VOC) detected are low and negligible for normal use
in line with the designated purpose of the respective
products (see chapter 7.2).
2.12 Environment and health during use
Environmental aspects: Hazards to water, soil and
air cannot arise from fibre cement flat sheets based on
current knowledge.
Health aspects: During normal usage according to
construction materials’ purpose, fixing and installation
guides are being observed, no health impairment is
known due to basic materials employed and their
behavior according to current knowledge.
2.13 Reference service life
The reference service life is non-relevant to this EPD
as it covers cradle to gate (up till the factory) (boundary
condition).
2.14
Extraordinary effects
Fire
For UCO Superflex, UCO Vistabord, UCO Decoceil,
and UCO Supertex Woodgrain panel:

Fire Propagation Index: range from 9.0-4.6,
according to BS 476-6:1989.

Surface spread of flame test: Class 1
surface spread of fame (actual result 0mm at
1.5m), according to BS 476-7:1997.
Water
UAC fiber cement board displays neutral reaction
when exposed to water. No dissolved substances are
found to be hazardous.
Mechanical destruction
Irrelevant
2.15 Re-use phase
Disassembly: The façade and flat sheets can be
removed through unscrewing or drilling the rivets,
depending on the fastening system. If large quantities
are assembled by plastering, it will be broken and
removed. For floorings with tiles on top, disassembly
will be done through destruction.
Reutilisation: In their undamaged form, the
dismantled form can be reused according to their
original purpose or as foundation wall protection. For
damaged form, it may be used as infill material for
UCO SolidWall System (material recycling).
Recycling: Possible uses as part of the constituent:
- for UCO SolidWall System infill material
- to make into a non-commercial value ‘timber blocks’
made of cementitious waste material for in house
application to reduce the use of actual timber block
2.16 Disposal
According to Malaysia Solid Waste and Public
Cleansing Management Act 2007 /Act 672/, remains of
Fibre Cement waste products from construction site or
from demolition can be disposed as solid waste. Waste
key ‘17 01 01 (Concrete)' in line with the European
Waste Catalogue /EWC/.
2.17 Further information
Further information on the products can be referred to
the “Product Specifications” from www.uac.com.my
3. LCA: Calculation rules
3.1
Declared Unit
Declared unit refers to the UAC Fibre Cement Boards
manufactured with the mixing of cement, silica sand,
pulp, alumina, silica fume and red oxide and dried
under the high pressure and temperature in the
autoclave machine.
4
All declared products show similar recipes with some
differences in dosage of pre-products for certain
products. The declared products are produced under
the same production condition and procedure. The
Environmental Product Declaration UAC Berhad – UAC Fibre Cement Board
average metric tonne fibre cement product is
calculated based on the annual production data.
The declared functional unit of this study is 1 metric
tonne of UAC Fibre Cement Boards with average bulk
density 1350 kg/m3.
Declared unit
Name
Declared unit
Gross density
Conversion factor to 1 kg
Value
Unit
1
1350
0.0007407
41
t
kg/m3
-
3.2
System boundary
Type of EPD: Cradle to gate.
The following processes were included in the A1-A3
production stage of UAC Fibre Cement Boards
manufacture:
- Manufacture of preliminary products (cement, sand,
pulp, alumina, silica fume and red pigment)
- Transportation of raw materials and preliminary
products to the plant
- Manufacturing process in the plan including energy,
manufacture of auxiliaries, disposal of residual
materials incurred and consideration of any emissions
incurred
- Manufacture of packaging materials
the transport expenses associated with all input and
output data taken into consideration. Accordingly,
material flows with a share of less than 1% were also
considered in this study. It can be assumed that the
total of all neglected processes does not exceed 5% in
the effective categories. Machinery, plants and
infrastructure required in the manufacturing process
are not taken into consideration.
3.5
Background data
The GaBi 4 software system for comprehensive
analysis developed by PE INTERNATIONAL AG was
used for modeling the Life Cycle Assessment (LCA).
The consistent data items contained in the GaBi
database are documented in the online GaBi
documentation center. The basic data in the GaBi
database was applied for energy, transportation, and
consumables. The LCA was primary developed based
on the Malaysia database. Average data from the other
regions were incorporated where Malaysia database is
not available.
3.6
Data quality
All background data records related to the UAC
operation were provided by UAC Berhad as well as
GaBi database. The background data that was used
was last revised less than 10 years ago.
3.7
Period under review
The LCA study was developed based on the operation
activities from January to December of 2011.
3.3
Estimates and assumptions
No other estimations or assumptions were made
regarding the specifications outlined in this section
(Chapter 3).
3.8
Allocation
No allocation rules were applied in the life cycle
assessment of the foreground data of the examined
products.
3.4
Cut-off criteria
All operating data, i.e. all of the starting materials used,
internal fuel consumption and electricity consumption,
all direct production waste as well as all emission
measurements available were taken into consideration
in the analysis. Assumptions were made as regards
3.9
Comparability
Basically, a comparison or an evaluation of EPD data
is only possible if all the data sets to be compared
were created according to EN 15804 and the building
context, respectively the product-specific
characteristics of performance, are taken into account.
4. LCA: Scenarios and additional technical information
The documentation of the RSL is not required for the
EPD of UAC Fibre Cement Boards as the entire life
cycle is not declared (Module A1-A3).
5
Environmental Product Declaration UAC Berhad – UAC Fibre Cement Board
5. LCA: Results
DESCRIPTION OF THE SYSTEM BOUNDARY (X = INCLUDED IN LCA; MND = MODULE NOT DECLARED)
Manufacturing
Transport from the
gate to the site
Assembly
Use
Maintenance
Repair
Replacement1)
Refurbishment1)
Operational energy
use
Operational water
use
De-construction
demolition
Transport
Waste processing
Disposal
ReuseRecoveryRecyclingpotential
END OF LIFE STAGE
Transport
USE STAGE
BENEFITS AND
LOADS
BEYOND THE
SYSTEM
BOUNDARYS
Raw material
supply
PRODUCT STAGE
CONSTRUCTI
ON PROCESS
STAGE
A1
A2
A3
A4
A5
B1
B2
B3
B4
B5
B6
B7
C1
C2
C3
C4
D
X
X
X
MND MND MND MND MND MND MND MND MND MND MND MND MND
MND
RESULTS OF THE LCA - ENVIRONMENTAL IMPACT: 1 tonne of UAC Fibre Cement Board
Parameter
Unit
A1-A3
Global warming potential
[kg CO2-Eq.]
Depletion potential of the stratospheric ozone layer
[kg CFC11-Eq.]
Acidification potential of land and water
[kg SO2-Eq.]
Eutrophication potential
[kg (PO4)3-- Eq.]
Formation potential of tropospheric ozone photochemical oxidants [kg Ethen Eq.]
Abiotic depletion potential for non fossil resources
[kg Sb Eq.]
Abiotic depletion potential for fossil resources
[MJ]
673.22
9.56E-6
3.31
0.39
0.26
9.71E-4
7586.41
RESULTS OF THE LCA - RESOURCE USE: 1 tonne of UAC Fibre Cement Board
Parameter
Unit
A1-A3
Renewable primary energy as energy carrier
Renewable primary energy resources as material utilization
Total use of renewable primary energy resources
Non renewable primary energy as energy carrier
Non renewable primary energy as material utilization
Total use of non renewable primary energy resources
Use of secondary material
Use of renewable secondary fuels
Use of non renewable secondary fuels
Use of net fresh water
[MJ]
[MJ]
[MJ]
[MJ]
[MJ]
[MJ]
[kg]
[MJ]
[MJ]
[m³]
2381.81
213.44
2595.25
7944.33
0.00
7944.33
19.39
0.00
0.00
11.52
RESULTS OF THE LCA – OUTPUT FLOWS AND WASTE CATEGORIES:
1 tonne of UAC Fibre Cement Board
Parameter
Unit
A1-A3
Hazardous waste disposed
Non hazardous waste disposed
Radioactive waste disposed
Components for re-use
Materials for recycling
Materials for energy recovery
Exported electrical energy
Exported thermal energy
[kg]
[kg]
[kg]
[kg]
[kg]
[kg]
[MJ]
[MJ]
2.61
1481.77
0.12
IND
IND
IND
IND
IND
6. LCA: Interpretation
Environmental Impacts
In term of environmental impacts, due to the energyand resources-intensity of the raw material production
processes, the cement production was recorded to be
the major contributor to the environmental indicators
for the production of 1 tonne UAC Fibre Cement
Board.
In overall, the production of 1 tonne of UAC Fibre
Cement Board contributed 693.28 kg CO2-eq of GWP,
9.71E-4 kg Sb-eq of ADPE and 7566.408 MJ of ADPF.
The carbon dioxide, carbon monoxide, nitrogen oxide
emitted during the cement production has significant
contribution towards EP, AP and POCP.
Resource Use
This study revealed that the manufacturing activities
within the UAC Plant have relatively lower
environmental impacts profile as compared to the raw
material production process. This is in grave contrast
to the transportation, which constantly contributed the
least to environmental impact as the 2 main raw
materials (cements and sands) were locally sourced.
6
The LCA study revealed that the manufacturing of 1
tonne of UAC Fibre Cement Board consumed 7944.33
MJ of PENRT and 2595.25 MJ of PERT. The use of
PERT was mainly resulted from the Malaysia’s energy
grid mix, of which 40% was hydro-electricity. The
production of raw material was responsible for 99% of
the overall secondary material (SM) due to the reuse
Environmental Product Declaration UAC Berhad – UAC Fibre Cement Board
and burning of the waste pulp during the pulp
production process. Lastly, the raw material
preparation process within the UAC Plant, especially
the hydropulper and sand grinding process were
responsible for 52% of the overall water consumption
(FW).
Output Flows and Waste Categories
The disposal of several type of machinery oils within
the UAC Plant have contributed to 73% of the overall
HWD; whilst the raw material extraction process was
responsible for 85% of the overall NHWD, which
primary consisted of waste paper. Finally, the use of
nuclear energy during the production of raw materials
(upstream process) was responsible for 95% of the
overall RWD.
7. Requisite evidence
7.1 Leaching Test
7.2 VOC emissions
Testing on the toxicity characteristic leaching
procedure (TCLP) using SW 846 6010 and 7473
methods were conducted for UAC Fibre Cement Board
(represented by Flexaboard and Superflex) where the
results are demonstarted in the table below.
The “ASTM D5116-06: Standard Guide for small smallscale environmental chamber determinations of
organic emissions from indoor materials/products”
testing conducted by TUV Singapore certified that UAC
Fibre Cement Board is:
Leaching Test
VOC emissions
Name
Arsenic (As)
Barium (Ba)
Cadmium (Cd)
Chromium (Cr)
Mercury (Hg)
Plumbum (Pb)
Selenium (Se)
Silver (Ag)
Value
Unit
< 0.018
≤ 0.16
≤ 0.0013
≤ 0.017
≤ 0.002
≤ 0.02
≤ 0.02
<0.01
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
Name
Value
Total VOC emission rate
0.17
Formaldehyde emission
<0.02
Phenylcyclohexene emission rate
Not
dectecte
d*
Phthalate emission
0.003
Total particle emission
<0.02
Unit
mg per
m^3 per
hour
mg per
m^3 per
hour
mg per
m^3 per
hour
mg per
m^3
mg per
m^3
* Detection level: 0.002 mg per m^3
8. References
Institut Bauen und Umwelt 2011
Institut Bauen und Umwelt e.V., Königswinter (pub.):
Generation of Environmental Product Declarations
(EPDs);
General principles
for the EPD range of Institut Bauen und Umwelt e.V.
(IBU), 2011-09
www.bau-umwelt.de
PCR 2011, Part A
Institut Bauen und Umwelt e.V., Königswinter (pub.):
Product Category Rules for Construction Products
from the range of Environmental Product Declarations
of Institut Bauen und Umwelt (IBU), Part A: Calculation
Rules for the Life Cycle Assessment and
Requirements on the Background Report. September
2012
www.bau-umwelt.de
ISO 14025
DIN EN ISO 14025:2011-10: Environmental labels and
declarations — Type III environmental declarations —
Principles and procedures
EN 15804
EN 15804:2012-04: Sustainability of construction
works — Environmental Product Declarations — Core
rules for the product category of construction products
7
Act 127
Laws of Malaysia Act 127 – Environmental Quality Act
1974 – Environmental Quality (Clean Air) Regulations,
1978
Act 139
Laws of Malaysia Act 139 – Factories and Machinery
Act 1967 – Factories and Machinery (Mineral Dust)
Regulations 1989
Laws of Malaysia Act 139 – Factories and Machinery
Act 1967 – Factories and Machinery (Noise Exposure)
Regulations 1989
Act 672
Laws of Malaysia Act 672 – Solid Waste and Public
Cleansing Management Act 2007
ASTM E90-09
Standard Test Method for Laboratory Measurement of
Airborne Sound Transmission Loss of Building
Partitions and Elements
ASTM D5116-06
Standard Guide for small small-scale environmental
chamber determinations of organic emissions from
indoor materials/products
Environmental Product Declaration UAC Berhad – UAC Fibre Cement Board
BS 476 Part 6.
Fire fropogation.
Source: http://www.colorcoatonline.com/en/technical/regulations/fire_performance/b
s476/
BS 476 Part 7.
Surface spread of flame.
Source: http://www.colorcoatonline.com/en/technical/regulations/fire_performance/b
s476/
BS EN 12467:2004
Fibre-cement flat sheets. Product specification and test
methods
European Waste Catalogue (EWC)
Chapter 17: Construction and demolition wastes
(including excavated soil from contaminated sites)
8
GaBi 4
GaBi 4: Software and database for life cycle
engineering. LBP, University of Stuttgart and PE
INTERNATIONAL AG, Leinfelden-Echterdingen, 2010
GaBi 4 Datasets
GaBi 4: Documentation of GaBi4-Datasets for life cycle
engineering. LBP University of Stuttgart and PE
INTERNATIONAL AG, 2010.
http://documentation.gabi-software.com/
MS1296
Malaysia Standard MS 1296: 2010 Fibre-Cement Flat
Sheets
SW 846
Test Methods for Evaluating Solid Waste, Physical /
Chemical Methods
Method 7473 - Mercury in Solids and Solutions by
Thermal Decomposition, Amalgamation, and Atomic
Absorption Spectrophotometry
Method 6010 - Inductively Coupled Plasma-Atomic
Emission Spectrometry
Environmental Product Declaration UAC Berhad – UAC Fibre Cement Board
Publisher
Institut Bauen und Umwelt e.V.
Rheinufer 108
53639 Königswinter
Germany
Tel
Fax
Mail
Web
+49 (0)2223 29 66 79- 0
+49 (0)2223 29 66 79- 0
info@bau-umwelt.com
www.bau-umwelt.com
Programme holder
Institut Bauen und Umwelt e.V.
Rheinufer 108
53639 Königswinter
Germany
Tel
Fax
Mail
Web
+49 (0)2223 29 66 79- 0
+49 (0)2223 29 66 79- 0
info@bau-umwelt.com
www.bau-umwelt.com
Author of the Life Cycle Assessment
PE INTERNATIONAL (Malaysia) Sdn.
Bhd.
Jalan 14/22, Right Angle 28-3
46100 Petaling Jaya, Selangor,
Malaysia
Tel
Fax
Mail
Web
+603 – 7960 3008
+603 – 7931 6269
info@pe-international.com
www.pe-international.com
Owner of the Declaration
UAC Berhad
Jalan Portland, Tasek Industrieal
Estate, 36
31400 Ipoh, Perak
Malaysia
Tel
Fax
Mail
Web
+605 – 291 2033
+603 – 291 7712
tan_kean_leong@uac.com.my
www.uac.com.my