Dal-Tile Corporation. Environmental Product Declaration CERAMIC, PORCELAIN, QUARRY AND MOSAIC TILE MANUFACTURING

Environmental Product Declaration Dal-Tile Corporation CERAMIC, PORCELAIN, QUARRY AND MOSAIC TILE MANUFACTURING www.daltile.com www.americanolean....
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Environmental Product Declaration

Dal-Tile Corporation

CERAMIC, PORCELAIN, QUARRY AND MOSAIC TILE MANUFACTURING

www.daltile.com

www.americanolean.com

www.marazziusa.com

www.ragno.it/en/ragno

www.mohawkflooring.com

Ragno Florence EPD Porcelain tile

According to ISO 14025

This declaration is an environmental product declaration (EPD) in accordance with ISO 14025. EPDs rely on Life Cycle Assessment (LCA) to provide information on a number of environmental impacts of products over their life cycle. Exclusions: EPDs do not indicate that any environmental or social performance benchmarks are met, and there may be impacts that they do not encompass. LCAs do not typically address the site-specific environmental impacts of raw material extraction, nor are they meant to assess human health toxicity. EPDs can complement but cannot replace tools and certifications that are designed to address these impacts and/or set performance thresholds – e.g. Type 1 certifications, health assessments and declarations, environmental impact assessments, etc. Accuracy of Results: EPDs regularly rely on estimations of impacts, and the level of accuracy in estimation of effect differs for any particular product line and reported impact. Comparability: EPDs are not comparative assertions and are either not comparable or have limited comparability when they cover different life cycle stages, are based on different product category rules or are missing relevant environmental impacts. EPDs from different programs may not be comparable.

PROGRAM OPERATOR DECLARATION HOLDER DECLARATION NUMBER DECLARED PRODUCT REFERENCE PCR DATE OF ISSUE PERIOD OF VALIDITY

UL Environment Dal-Tile Corporation 4786107873.102.1

MCT-Florence Porcelain Tile NSF PCR for Flooring (Carpet, Resilient, Laminate, Ceramic, and Wood) April 11, 2014 5 Years Product definition and information about building physics Information about basic material and the material’s origin Description of the product’s manufacture CONTENTS OF THE Indication of product processing DECLARATION Information about the in-use conditions Life cycle assessment results Testing results and verifications NSF International The PCR review was conducted by: Accepted by PCR Review Panel [email protected] This declaration was independently verified in accordance with ISO 14025 by Underwriters Laboratories Wade Stout, ULE EPM ☐ INTERNAL ☒ EXTERNAL This life cycle assessment was independently verified in accordance with ISO 14044 and the reference PCR by: Thomas Gloria, Life-Cycle Services, LLC

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Ragno Florence EPD Porcelain tile

According to ISO 14025

Ragno Always leading while learning. This simple, yet wisdom-filled phrase has been the guiding force behind Ragno USA’s remarkable success in the manufacturing of elegant, refined porcelain surfaces. Fueled by the pioneering spirit of Ceramiche Ragno S.p.A, founded over 60 years ago in Fiorano, Italy, and backed by a global leader as part of the Marazzi Group, Ragno USA has distanced itself from the competition with world-class porcelain tile collections made right here in America. Ragno USA has transferred the technology and know-how from Italy to its state of the art facilities in the USA, providing Italianinspired porcelain tiles with high-quality and design-savvy styles.

• Affresco • Arte • Boardwalk • Burgundy •Calabria • Cambridge Oak • Cleftstone • Coliseum • Cometstone • Concerto • Costa Bella • Eclipse • Eternal Limestone • Flash • Florentia • India

• Just • Maraja • Mediterranean • Monte Verino • Origins • Princeps • Pure • Rapture • Riverstone • Stone • Stone Collection • Tuscan Stone • Vatican Gallery • Vesta • Western Stone • Woodland Terrace

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Ragno MCT – Florence EPD Porcelain tile

According to ISO 14025

Product Definition Product Classification and Description Ceramic tile is a mixture of multiple mineral-based natural materials, including but not limited to clay, sand, feldspar, talc, nepheline and shale. The tiles are either pressed or extruded into the desired shape and fired in kilns at high temperatures. Ceramic tile is fire resistant, non-combustible, durable (lasts a lifetime) and extremely easy to maintain. As floor and wall coverings, ceramic tile products provide dual functions. They serve 1) an aesthetic function as a design component, and 2) a technical function as a building finishing material. As a building material, ceramic tile is capable of withstanding a wide range of environmental stresses. The versatility of ceramic tile is further enhanced by the almost extensive ranges of colors, textures, and decorative motifs offered by Dal-Tile under multiple brand names. Tile products are available in a wide range of sizes from less than 1" x 1" to more than 24" x 24". Ceramic tiles are classified by their shaping or production method (either dry pressed or extruded), and the level of water absorption measured as a percentage. Classifications of Ceramic Tile - Wear Ratings from the Porcelain Enamel Institute     

Group I Classification - Tile that is suitable for residential bathrooms with light foot traffic. Group II Classification - Tile that can be used in residential areas, but not areas with high foot traffic, such as in kitchens, foyers, laundry rooms, etc. Group III Classification - Tile that is recommended for all residential installations with normal foot traffic. Group IV Classification - Tile that is suited for light to medium commercial applications, such as offices, sales rooms. Group V Classification - Tile used in heavy commercial traffic areas and is suited for exterior areas, shopping centers, airports, hotel lobbies, and public walkways.

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Ragno MCT – Florence EPD Porcelain tile

According to ISO 14025

Range of Applications Ceramic, Porcelain, Quarry, and Mosaic tile products are commonly used in commercial, light commercial, institutional, and residential interior and exterior applications. Product Standards The products considered in this EPD meet or exceed the following Technical Specifications: • •

ANSI A137.1 - American National Standard Specifications for Ceramic Tile ISO 10545 - International Organization for Standardization Specifications for Ceramic Tile

Fire Testing: • • •

Classification: A Frame Spread: 0 Interior wall: ASTM E84, NFPA 255, UL 723 Interior floor: ASTM E 648, NFPA 253

Smoke Developed: 0

Product Characteristics Table 1: MCT - Florence Nominal Value Class

Porcelain

Grade

Standard 6x24, 6x36, 8x12, 9x36, 12x12, 12x24, 13x13, 16x16, 18x18, 20x20, trim

Nominal thickness 2

Product weight Dimensional categories

Maximum Value

P1

Tile type

Nominal facial area

Minimum Value

3.97 lbs/ft 2 (19,363 g/m ) Calibrated and Rectified*

* only some product styles are available in a rectified format

2

2

144 in 2 (92,903 mm )

400 in 2 (258,064 mm )

0.35 in (9 mm) 2 3.36 lbs/ft 2 (16,405 g/m )

0.43 in (11 mm) 2 4.77 lbs/ft 2 (23,265 g/m )

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Ragno MCT – Florence EPD Porcelain tile

According to ISO 14025

Material Content Table 2: Material Content of the Product – MCT Florence Availability Component

Material

Renewable Body

Glaze

Recycled

Origin of raw materials

Pre-Consumer

US / Canada

Mass % Non-renewable

Recycled material

42.9%

Clay

40.4%

Mineral perpetual

US

Sand

13.5%

Mineral perpetual

US

Glaze

3.3%

Mineral perpetual

US

Production of Main Materials Clay Clay is an earthen material comprised of extremely fine particles of minerals, organic matter, and trace amounts of naturally occurring metal oxides. It can be molded when wet and hardened into shape by heating at high temperatures. Clay is mined directly from the earth and can be used in the production of ceramic tiles with minimal processing. While clay is the primary ingredient in any tile, it is often blended with fluxing minerals to achieve the desirable characteristic of the tile product. The mined clay is assumed to be of North American origin. Sand Sand is a granular material made of fine mineral particles. While sand does not have a defined mineral composition, most commonly it is comprised of silica in the form of quartz. Sand is a common additive in tile production to give the fired tiles size stability. Glaze Glaze is a smooth, protective coating commonly applied to tile products. Color and other aesthetic qualities can be given to the tiles through a glaze coating. Glazing materials are comprised of glass frits, clays, aluminum oxide, and water. It is sprayed, rolled or poured onto the tile, and fired to form an inseparable top coating.

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Ragno MCT – Florence EPD Porcelain tile

According to ISO 14025

Production of the Floor Covering

Figure 1: Process flow diagram for MCT - Florence tile

Production Waste Most scrap and waste is recycled back into the product, but the different sites produce a small amount of waste 2 (between 0.006 and 0.15 lbs of waste per ft of tile) which is sent offsite to a landfill. All production facilities have developed, implemented and are maintaining internal EHS management systems. This includes over 30 formal written Safety & Health Programs with associated training programs to ensure all workers engaged in the manufacturing processes are aware of any hazards that may exist and are fully protected against them. Of particular importance with regard to Industrial Hygiene issues, each facility has site-specific respiratory protection and hearing conservation programs. Safety programs include formal Lock Out-Tag Out, Machine Guarding, Confined Space, Electrical Safety, and many others. Further, all sites have programs and procedures in place to ensure they operate in compliance with applicable environmental requirements. In addition to the internal systems implemented to ensure EHS compliance and protection, some facilities have formalized their programs and procedures into 3rd party certified written Management Systems such as OSHA VPP, OHSAS 18001, and ISO 14001. See Section 1 Product Declarations, Accreditations for specific certifications achieved by the facility that manufactured the products that are the subject of this Declaration.

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Ragno MCT – Florence EPD Porcelain tile

According to ISO 14025

Delivery and Installation of the Floor Covering Delivery Dal-Tile Corporation produces multiple brands of tile products including Daltile, American Olean, Marazzi, Ragno, and Mohawk. The company has over 10 manufacturing plants in the US and Mexico and thus creates the opportunity to provide a regionally manufactured product to more building projects than any other tile manufacturer. For purposes of this study, the average transport distance from manufacturing to construction site was assumed to be 500 miles by truck. LCA impacts associated with installation of the tile products in the building project are included. Installation 2

2

Mortar is required (0.833 lbs / ft ) for product installation. Sanded grout is also required (0.067 lbs / ft . During installation, approximately 4.5% of the total material is lost as waste. Though some of this waste could be recycled, this scrap is modeled as being disposed of in a landfill.

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Ragno MCT – Florence EPD Porcelain tile

According to ISO 14025

Waste Based on current best information a small amount of installation waste is incinerated for energy recovery, but for the purposes of this EPD 100% of all such waste is assumed to be disposed of in a landfill. Packaging Primary packaging is 100% cardboard, but secondary/tertiary packaging are film and pallets. 100% of the packaging waste is recyclable. However, for this study, no documentation is available to quantify the percentage of packaging which is actually recycled, therefore all packaging waste is assumed to be sent to a landfill. Landfill emissions from cardboard packaging are allocated to installation. Electricity generated from landfill gas (produced from the decomposition of bio-based packaging) is ignored since the cut-off approach is applied to recycled materials.

Use stage The service life of ceramic tile is unique in that it’s not dependant on the amount of floor traffic and the type and frequency of maintenance. The level of maintenance is dependent on the actual use and desired appearance of the floor. For the NSF Flooring PCR, the building’s Reference Service Life (RSL) is assumed to be 60 years. Since ceramic tile is expected to last at least as long as the building itself, the product will also have an RSL of 60 years. Since the EPD must present results for both one-year and 60-year time periods, impacts are calculated for both time horizons. In the case of one-year results, the use phase impacts are based on the cleaning and maintenance model for one year. In the case of 60-year results, the production, transport, installation, and end-of-life are scaled to reflect replacements during the 60 year period; use phase impacts are scaled to represent maintenance for 60 years. Cleaning and Maintenance Tile products should be cleaned routinely with an all-purpose, low VOC household or commercial cleaner. The product chosen should also be grout joint cleaning compatible. The type of product may vary depending on the tile application and use. A multipurpose spray cleaner, which removes soap scum, hard water deposits, and mildew designed for everyday use, can be used on wall tile areas in residential baths and showers. For more information, please refer to: www.daltile.com/information/care-and-maintenance The recommended cleaning regime is highly dependent on the use of the premises where the floor covering is installed. In high traffic areas more frequent cleaning will be needed compared to areas where there is low traffic. For the purposes of this EPD, average maintenance is presented based on typical installations. Table 3: Cleaning Process Level of use

Cleaning Process

Dust mop Commercial / Residential / Industrial Damp mop / neutral cleaner Spray buff / finish restorer

Cleaning Frequency

Consumption of energy and resources

Daily

None

Weekly Monthly

Hot water Neutral detergent Floor finish Electricity

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Ragno MCT – Florence EPD Porcelain tile

According to ISO 14025

This cleaning process translates to: Table 4: Cleaning Inputs Amount

Units

Detergent

119

mL / m / yr.

Electricity

0.022

kWh / m / yr.

Water

5.8

L / m / yr.

2

2

2

Prevention of Structural Damage Interior floor covering should not be installed until any and all structural damage has been adequately repaired and determined to be code compliant. Surfaces must be structurally sound, stable and rigid enough to support the ceramic, porcelain, quarry and/or mosaic tile finishes.

Health Aspects During Usage The tile products in this EPD comply with the VOC emissions limitations established by the California Department of Public Health and the Southern California Air Resources Board. In fact, VOC emissions were measured to be "nondetect" when analyzed in accord with the CA DPH Standard Practice for Testing of Volatile Organic Emissions Using Small-Scale Environmental Chambers (DPH Standard - Section 01350). Further, all of the LEED Green Building Rating Systems state that these tile products are considered to be inherently Low Emitting Materials and qualify for Indoor Environmental Quality Credit Point(s) without the need for any VOC emissions testing. This is because they meet the criteria of being mineral based and post-firing, do not contain organic-based coatings, binders or sealants.

End of Life Because these tile products are comprised primarily of naturally occurring mineral based materials and no hazardous ingredients are added during the manufacturing process, they are basically inert and can be used in multiple applications: e.g., clean fill material in land reclamation/contouring projects, base or substrate material for roadways and/or parking lots, replacement for raw materials used in cement or brick kilns, etc. Dal-Tile also has the ability to "take-back" tile at the end of its useful life under our R3 Program (Recovering and Reusing Resources). However, knowledge of the actual use of tile removed during demolition projects is extremely limited to nonexistent. Consequently, for purposes of this EPD, we have taken the most conservative approach and assumed that 100% of all tile removal waste is disposed of in a landfill.

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Ragno MCT – Florence EPD Porcelain tile

According to ISO 14025

Life Cycle Assessment A full Life Cycle Assessment has been carried out according to ISO 14025, 14040 and 14044, per the Product Category Rules (PCR) for Flooring: Carpet, Resilient, Laminate, Ceramic, Wood, as published by NSF International (2012). The following life cycle stages are considered: o Product stage o Construction stage o Use stage o End-of-life stage o Benefits and loads beyond the product system boundary The main purpose of EPDs is for use in business-to-business communication. As all EPDs are publicly available via the Program Operator and therefore are accessible to the end consumer, they can also be used in business-toconsumer communication. Functional Unit Description The declaration refers to the functional unit of 1m² installed floor covering. 1m² is equivalent to 10.76 ft². Cut-off Criteria No cut-off criteria were applied in this study. All reported data was incorporated and modeled using best available Life Cycle Inventory (LCI) data. Background Data As a general rule, specific data derived from specific production processes or average data derived from specific production processes shall be the first choice as a basis for calculating LCA results. For life cycle modeling of the considered products, the GaBi 6 Software System for Life Cycle Engineering, developed by PE INTERNATIONAL AG, has been used to model the product systems considered in this assessment. All relevant background datasets are taken from the GaBi 2013 software database. The datasets from the GaBi database are documented in the online documentation / GaBi 6 2013D/. To ensure comparability of results in the LCA, the basic data of GaBi database were used for energy, transportation and auxiliary materials. Data Quality A variety of tests and checks were performed throughout the project to ensure high quality of the completed LCA. Checks included an extensive review of project-specific LCA models as well as the background data used.

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Ragno MCT – Florence EPD Porcelain tile

According to ISO 14025

Temporal Coverage Primary data collected from Dal-Tile is based on 12 month averaged data representing the calendar year of 2012. Background datasets are all based on data from the last 3 years (since 2010), with the majority of datasets based on data from 2012.

Technological Coverage Data on material composition and manufacturing are primary data from Dal-Tile. The raw material inputs in the calculation for this LCA are based on product specifications and bill of materials. Waste, emissions and energy use are based on annual total purchases divided by annual production during the reference year.

Geographical Coverage This background LCA represents Dal-Tile products produced in the United States and Mexico. Manufacturing energy was representative for each country included, but proxy datasets were used as needed for raw material inputs to address lack of data for a specific material or for a specific geographical region. These proxy datasets were chosen for their technological representativeness of the actual materials. System Boundaries The scope of the study includes raw material sourcing / extraction, manufacturing, installation, use, and disposal of ceramic tile. Table 5 summarizes major components being considered for inclusion and exclusion from the study and have been shaped by the need to accurately reflect the environmental burden associated with the functional unit. Table 5: System Boundaries

     

Included Raw materials production (chemicals, minerals, etc.) Use of auxiliary materials, water, and energy during manufacturing, installation, and use Packaging of products Emissions to air, water, and soil during manufacturing, installation, and use Transport of raw materials and finished products Disposal

    

Allocation

Co-Product Allocation No co-product allocation occurs in the product system.

Multi-Input Processes Allocation No multi-input allocation occurs in the product system.

Excluded Construction of capital equipment Maintenance and operation of support equipment Human labor and employee commute Overhead (heating, lighting, warehousing) of manufacturing facilities Internal transportation (within a manufacturing facility)

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Ragno MCT – Florence EPD Porcelain tile

According to ISO 14025

Reuse, Recycling, and Recovery Allocation The cut-off allocation approach is adopted in the case of any post-consumer recycled content, which is assumed to enter the system burden-free. Only environmental impacts from the point of recovery and forward (e.g., collection, sorting, processing, etc.) are considered. Product and packaging waste is modeled as being disposed in a landfill rather than incinerated or recycled. Plastic and other construction waste is assumed to be inert in landfills so no system expansion or allocation is necessary as landfill gas is not produced. In the case of landfill gas generated by the decay of bio-based packaging after installation, the cut-off approach is used; no credit is given for capture or utilization of the landfill gas.

Impact Categories The impact assessment results are calculated using characterization factors published by the University of Leiden’s CML 2001 – Apr. 2013. Abbreviations for the impacts described here are used in the results tables below. •



Environmental Impact Categories (CML 2001): o

Abiotic Depletion, Elements

(ADP-e)

[kg Sb-eq];

o

Abiotic Depletion, Fossil

(ADP-f)

[MJ];

o

Acidification Potential

(AP)

[kg SO2 eq];

o

Eutrophication Potential

(EP)

[kg Phosphate eq];

o

Global Warming Potential

(GWP)

[kg CO2 eq];

o

Ozone Depletion Potential

(ODP)

[kg R 11 eq];

o

Photochemical Oxidant Formation Potential

(POCP)

[kg Ethene eq];

Environmental Indicators: o o o o o

Primary Energy of non-renewable resources Primary energy of renewable resources Secondary materials Non-renewable material sources Output flows

[MJ]; [MJ]; [kg]; [kg]; [kg]

Results Results for one square meter installed ceramic tile are presented in the sections below.

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Ragno MCT – Florence EPD Porcelain tile

According to ISO 14025

Life Cycle Inventory Analysis Primary Energy Demand Primary energy resources and water use are presented below. Table 6: Primary energy, non-renewable for all life cycle stages of 1 square meter of ceramic tile for 1 year Use [MJ]

Table 7: Primary energy, renewable for all life cycle stages of 1 square meter of ceramic tile for 1 year Use [MJ]

Renewable Primary Energy

Non-Renewable Primary Energy

Other Resources and Wastes Secondary material and secondary fuel (fossil and renewable) consumption are presented below.

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Ragno MCT – Florence EPD Porcelain tile

According to ISO 14025

Table 8: Other resources and wastes for all life cycle stages of 1 square meter of ceramic tile for 1 year Use [kg]

Life Cycle Impact Assessment The impact assessment results are calculated using characterization factors published by the University of Leiden's CML 2001 – Apr. 2013 methodology. Table 9: CML Impact assessment results of 1 square meter for 1 year use

Table 10: CML Impact assessment results of 1 square meter for 60 year use

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Ragno MCT – Florence EPD Porcelain tile

According to ISO 14025

Figure 2: CML Impact assessment results of 1 square meter for 1 year use

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Ragno MCT – Florence EPD Porcelain tile

According to ISO 14025

Figure 3: CML Impact assessment results of 1 square meter for 60 year use

Interpretation When considering a 60 year product life, energy for manufacturing and recommended maintenance are the two largest contributors in almost all impact categories considered. The production of raw materials also represents a substantial fraction of the life cycle impacts, especially for the Abiotic Depletion and Ozone Depletion categories. When considering a 1-year product life, production of raw materials and energy for manufacturing are by far the two largest contributors in all impact categories considered. The transportation of raw materials and products is also a relevant contributor to all of the life cycle impacts considered.

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Ragno MCT – Florence EPD Porcelain tile

According to ISO 14025

References

GaBi 6 2013

PE INTERNATIONAL AG; GaBi 6: Software-System and Database for Life Cycle Engineering. Copyright, TM. Stuttgart, Echterdingen, 19922013.

GaBi 6 2013D

GaBi 6: Documentation of GaBi 6: Software-System and Database for Life Cycle Engineering. Copyright, TM. Stuttgart, Echterdingen, 19922013. http://www.gabi-software.com/support/gabi/

ISO 14025

ISO 14025:2011-10 Environmental labels and declarations - Type III environmental declarations - Principles and procedures

ISO 14040

ISO 14040:2009-11 Environmental management - Life cycle assessment - Principles and framework

ISO 14044

ISO 14044:2006-10 Environmental management - Life cycle assessment - Requirements and guidelines

NSF PCR 2012

NSF Product Category Rule for Flooring: Carpet, Resilient, Laminate, Ceramic, Wood