ENVIRONMENTAL PRODUCT DECLARATION Dalsan Gypsum

ENVIRONMENTAL PRODUCT DECLARATION
as per ISO 14025 and EN 15804
Owner of the Declaration
Dalsan Gypsum Industry and Trade Inc.
Programme holder
Institut Bauen und Umwelt e.V. (IBU)
Publisher
Institut Bauen und Umwelt e.V. (IBU)
Declaration number
EPD-DGI-20130062-CBD1-EN
Issue date
18.07.2013
Valid to
17.07.2018
Gypsum Plasterboards
Dalsan Gypsum Industry and Trade Inc.
www.bau-umwelt.com / https://epd-online.com
Umwelt Produktdeklaration Name des Herstellers – Name des Produkts
General Information
Dalsan Gypsum Industry and Trade
Inc.
Gypsum Plasterboards
Programme holder
IBU - Institut Bauen und Umwelt e.V.
Rheinufer 108
D-53639 Königswinter
Owner of the Declaration
Dalsan Gypsum Industry and Trade Inc.
1.cadde Sincap sokak, Büyüksanayi No:12
06060 Ankara
Declaration number
EPD-DGI-20130062-CBD1-EN
Declared product / Declared unit
Gypsum plasterboards / 1 m2
This Declaration is based on the Product
Category Rules:
Plasterboard, 07-2012
(PCR tested and approved by the independent expert
committee)
Scope:
Issue date
18.07.2013
This declaration is relevant to gypsum plasterboards
manufactured by Dalsan at Ankara and Gebze
production plants in Turkey. The EPD applies to all
types of plasterboards. It is described as declaration of
an average product as an average from several of the
manufacturer’s plants. The owner of the declaration
shall be liable for the underlying information and
evidence.
Valid to
17.07.2018
Verification
Prof. Dr.-Ing. Horst J. Bossenmayer
(President of Institut Bauen und Umwelt e.V.)
Prof. Dr.-Ing. Hans-Wolf Reinhardt
(Chairman of SVA)
The CEN Norm EN 15804 serves as the core PCR
Independent verification of the declaration and data
according to ISO 14025
internally
x externally
Dr. Olivier Muller
(Independent tester appointed by SVA)
Product
Product description
Gypsum plasterboard is a composite material which is
mainly dehydrated gypsum and plasterboard liner facer
or fiberglass mat facer. They also include other raw
materials such as paraffin, plasticizer, starch, surface
protective, accelerators, perlite, foaming agent,
adhesive, retarders, fiberglass and recycled
plasterboard.
Manufacturing starts with the stucco preparation
(grinding, calcination and separation) at the plaster
plant. After receive of the raw material gypsum mineral
(CaSO4.2H2O) to the Dalsan’s plant, it is grinded and
heated to remove 75% of combined water, resulting in
the formation of stucco (calcium sulphate hemihydrate)
(CaSO4.½H2O). After calcination, stucco is mixed with
water and other necessary additives. The slurry formed
is poured on the bottom paperboard liner. The upper
paperboard liner is then pulled by the line to cover the
board as a top facer. Once setting completes at the
setting belt, it is cut automatically with a knife. The
excess water to make liquid slurry is then evaporated
by plasterboard dryer to obtain dry boards. At final
stage the plasterboard is trimmed and then packaged
for delivery.
Reference standards applied are TS EN 520 +A1 for
all except EN 15283-1 for ALLEV A1 and BoardeX.
Delivery is made with a packaging of average 50 units
per pallet.
2
Application
Dalsan manufactures various plasterboard products
with different specifications for different applications.
The main products that are part of this EPD are:
ALLEV beyazı (standard plasterboard), ALLEV yeşili
(plasterboard with reduced water absorption rate),
ALLEV kırmızısı (plasterboard with improved core
adhesion at high temperature), BoardeX (exterior
sheathing board), ALLEV bordosu (plasterboard with
improved core adhesion at high temperature and with
reduced water absorption rate) and finally ALLEV A1
(A1 classification non-combustible plasterboard). Their
area of applications are:
ALLEV beyazı: partition walls, drywall linings and
suspended ceilings.
ALLEV yeşili: partition walls, drywall linings and
suspended ceilings where water and moisture
resistance is required.
ALLEV kırmızısı: partition walls, drywall linings and
suspended ceilings where fire resistance is required.
ALLEV bordosu: partition walls, drywall linings, and
suspended ceilings in places (bathrooms, toilets,
kitchens, messes, and attics) where resistance to
water and humidity as well as resistant to fire is
required.
BoardeX: an exterior sheathing board used in exterior
wall, with its reinforced core against humidity and
special orange fiberglass facer.
Environmental Product Declaration Dalsan Gypsum Industry and Trade Inc. – Gypsum Plasterboards
ALLEV A1: interior partition walls, in the construction of
suspended ceilings, shaft walls and ventilation ducts,
and in the reinforcing of steel and wooden structural
components for fire resistance.
Technical Data
Technical data for Dalsan Plasterboards are shown
below:
Constructional data
Name
Value
Gross density
Modulus of elasticity
Thermal conductivity
Calculation value for thermal
conductivity
Water vapour diffusion resistance
factor
Sound absorption coefficient (only
with reference to the
corresponding component design)
Water absorption (by weight)
Fire resistance
Flexural strenght load
(Transverse)
Flexural strenght load
Unit
650 - 900
kg/m3
2900 N/mm2
3500
0.22 - 0.25 W/(mK)
0.25
W/(mK)
10
-
10
%
<= 5-10
A1 /
A2,s1,d0
%
210
N
550
N
(Longitudinal)
Base materials / Ancillary materials
Gypsum plasterboards are made of raw materials
such as stucco (calcium sulphate hemihydrate), water,
paperboard liner, recycled plasterboard, paraffin,
plasticizer, starch, surface protective, fiberglass mats,
accelerator, perlite, foaming agent, adhesive, retarders
and fiberglass. Major constituents are stucco, water
and plasterboard liner.
Very small amount of biocides (C8H12INO2 CAS:
55406-53-6) as an additive are used.
There are no products that can be included in
“Candidate List of Substances of Very High Concern
for Authorisation” and raw materials used are not part
of the EU REACH regulation.
Plasterboards products have a long life and can be
recycled or disposed designated landfill sites at the
end of their useful life.
Reference service life
This EPD is relevant to cradle to factory gate as well
as disposal of product after use. Hence no reference to
useful life is required.
LCA: Calculation rules
Declared Unit
The declared unit, the mass reference and the
conversion factor to 1 kg must be indicated in the
appropriate table as declared.
The declared unit is 1 m2 gypsum plasterboards with
an average weight 8.85 kg in line with the PCR
document for Plasterboard.
The dimensions of standard plasterboard are
2500x1200x12.5mm with an average weight of 26.6
kg.
accordance with valid legal requirements. There is no
wastewater from the production process in both plants.
However, there is wastewater arising from general use
within the factory. This is very small and treated in two
biological wastewater treatment plants in Ankara and
sedimentation pits in Gebze. The treated water is used
in irrigation of gardens or discharged to municipality
drainage network. Gebze plant is designed to collect
rainwater which is used in the process.
The process flow diagram is shown below:
Declared unit
Name
Declared unit
Declared unit
Conversion factor to 1 kg
Value
Unit
0.0125
1
8.85
m3
m2
-
System boundary
This is a cradle to gate EPD including disposal of
product after use. The system boundary for the Life
Cycle Assessment covers raw materials (A1), transport
(A2), manufacturing (A3) and disposal (C4).
‘Raw materials stage’ includes extraction and
processing of raw materials. ‘Manufacturing stage’
involves further processing of raw materials required
by the production, mixing stucco with excess water and
any additives, followed by setting (board forming) and
cutting, drying, trimming and packaging. ‘Transport
stage’ is only relevant for delivery of all raw materials
to the plant and forklift usage within the factory.
With regard to the end of life, all plasterboards end up
at landfill as their final fate. The benefit from open-loop
recycling and re-use is not relevant for this LCA work.
The waste arising from forming, drying and trimming
are utilized internally (closed-loop).
In addition, all waste coming from the production and
service processes of Dalsan is managed in
3
Cut-off criteria
Where there are no data available, raw materials that
are a minor constituent of the product amounting less
than 1% of total raw materials are excluded in this
study.
Comparability
Basically, a comparison or an evaluation of EPD data
is only possible if all the data sets to be compared
Environmental Product Declaration Dalsan Gypsum Industry and Trade Inc. – Gypsum Plasterboards
were created according to EN 15804 and the building
context, respectively the product-specific
characteristics of performance, are taken into account.
This EPD is comparable with gypsum plasterboards
that comply with the PCR document Part B:
Plasterboard and are evaluated according to EN 15804
norms.
LCA: Scenarios and additional technical information
The impact indicators were performed according to
LCA standard (ISO 14040/44) using SimaPro software
with ecoinvent (v: 2.2) database.
Reuse-Recovery-and Recycling potential (D)
All gypsum plasterboards end up at construction and
demolition waste landfills. For manufacturing stage,
closed-loop scenario was used. Therefore, no possible
benefits of open-loop recycling and reuse were taken
into account in the LCA work here.
GREENGUARD Certification
Some of the products covered by this EPD have also
been awarded GREENGUARD certification. It is
awarded to products that protect human health and
quality of life by improving indoor air quality and
reducing chemical exposure when they are in use. The
following products were awarded GREENGUARD
Indoor Air Quality Certification® and GREENGUARD
Children & SchoolsSM Certification: ALLEV beyazı,
ALLEV bordosu, ALLEV kırmızısı and also ALLEV
yeşili.
4
Environmental Product Declaration Dalsan Gypsum Industry and Trade Inc. – Gypsum Plasterboards
LCA: Results
The results of the LCA with the indicators as per EPD requirement are given in the following tables for product
manufacture (A1, A2, A3) and the loads beyond the system boundaries (C4).
DESCRIPTION OF THE SYSTEM BOUNDARY (X = INCLUDED IN LCA; MND = MODULE NOT DECLARED)
BENEFITS AND
LOADS
BEYOND THE
SYSTEM
BOUNDARYS
Use
Maintenance
Repair
Replacement1)
Refurbishment1)
Operational energy
use
Operational water
use
De-construction
demolition
Transport
A3
A4
A5
B1
B2
B3
B4
B5
B6
B7
C1
C2
X
X
X
ReuseRecoveryRecyclingpotential
Constructioninstallation process
A2
Disposal
Transport
A1
Waste processing
Manufacturing
END OF LIFE STAGE
Transport
USE STAGE
Raw material
supply
PRODUCT STAGE
CONSTRUCTI
ON PROCESS
STAGE
C3
C4
D
X
MND
MND MND MND MND MND MND MND MND MND MND MND MND
RESULTS OF THE LCA - ENVIRONMENTAL IMPACT: 1 m2 of gypsum plasterboards
Parameter
Unit
Global warming potential
[kg CO2-Äq.]
Depletion potential of the stratospheric ozone layer
[kg CFC11-Äq.]
Acidification potential of land and water
[kg SO2-Äq.]
Eutrophication potential
[kg PO43-- Äq.]
Formation potential of tropospheric ozone photochemical oxidants [kg Ethen Äq.]
Abiotic depletion potential for non fossil resources
[kg Sb Äq.]
Abiotic depletion potential for fossil resources
[MJ]
A1 - A3
C4
1.977E+0
2.324E-7
4.331E-3
1.662E-3
1.317E-3
1.709E-2
3.543E+1
9.323E-2
2.457E-8
5.29E-4
1.354E-4
2.108E-4
1.123E-3
2.586E+0
RESULTS OF THE LCA - RESOURCE USE: 1 m2 of gypsum plasterboards
Parameter
Unit
A1 - A3
C4
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]
1.43E+0
0
1.43E+0
3.543E+1
0
3.543E+1
2.112E-2
1.921E-2
0
1.921E-2
2.586E+0
0
2.586E+0
2.701E-3
RESULTS OF THE LCA – OUTPUT FLOWS AND WASTE CATEGORIES:
1 m2 of gypsum plasterboards
5
Parameter
Unit
A1 - A3
C4
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]
3.985E-4
1.036E-2
-
8.85E+0
-
Environmental Product Declaration Dalsan Gypsum Industry and Trade Inc. – Gypsum Plasterboards
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
ISO 9001
DIN EN ISO 9001,Quality Management SystemRequirements
ISO 14040-44
DIN EN ISO 14040:2006-10, Environmental
management - Life cycle assessment - Principles and
framework (ISO 14040:2006) and Requirements and
guidelines (ISO 14044:2006)
6
PCR 2011, Part B
PCR Guidance-Texts for Building-Related Products
and Services, from the range of Environmental Product
Declarations of Institut Bauen und Umwelt (IBU), Part
B: Requirements on the EPD for plasterboard, July
2012, www.bau-umwelt.de
Ecoinvent
Ecoinvent Centre, www.ecoinvent.org
SimaPro
SimaPro LCA Package, Pré Consultants, the
Netherlands, www.pre-sustainability.com
TS EN 520+A1
Gypsum plasterboards - Definitions, requirements and
test methods
TS EN 15283-1
Gypsum boards with fibrous reinforcement Definitions, requirements and test methods - Part 1:
Gypsum boards with mat reinforcement
ASTM D3273
Standard Test Method for Resistance to Growth of
Mold on the Surface of Interior Coatings in an
Environmental Chamber
TS EN 13501
Fire classification of construction products and building
elements-Part 1: Classification using test data from
reaction to fire tests
GREENGUARD Certification
www.GREENGUARD.org
Environmental Product Declaration Dalsan Gypsum Industry and Trade Inc. – Gypsum Plasterboards
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
Owner of the Declaration
Dalsan Gypsum Industry and Trade
Inc.
1.cadde Sincap sokak, Büyüksanayi
No:12
06060 Ankara
Turkey
Tel
Fax
Mail
Web
+90 312 303 49 49
+90 312 341 25 69
dalsan@dalsan.com.tr
www.dalsan.com.tr
Author of the Life Cycle Assessment
Metsims Sustainability Consulting
Clear Water Place 4
OX27NL Oxford
UnitedKingdom
Tel
Fax
Mail
Web
+44 755 735 14 76
+44 186 551 04 78
info@metsims.com
www.metsims.com