C e r t a i nTe e d
Fence, Railing and Decking Life Cycle Assessment Report
CertainTeed Fence, Rail and Deck
Life Cycle Assessment
Executive Summary This life cycle assessment (LCA) was conducted for vinyl rail, vinyl fence and composite rail products manufactured by CertainTeed Fence, Rail and Deck. The product lines for this study include: Bufftech (vinyl fence), Kingston (vinyl rail) and Panorama (composite rail). Cradle-to-grave impacts are reported per eight feet and illustrate a range of possible impacts. This work was performed by Sustainable Solutions Corporation for CertainTeed. The objective of CertainTeed in commissioning this study was to quantify and understand the environmental impacts throughout the life cycle of the products; as a tool in the product design process of the products; and as an input to the BEES (Building for Environmental and Economic Sustainability) life cycle product database. The data was submitted to NIST for publication in October 2014 and will be found in the database which can be located at http://ws680.nist.gov/Bees. LCA is a rigorous study of the inputs and outputs of a particular product which provides a scientific basis for evaluating the impacts throughout the life cycle. LCA is an alternative to the single-criterion decision-making that currently guides many environmental choices. It enables a deeper understanding of the environmental footprint, which benefits manufacturers in improving their product’s environmental performance and their manufacturing processes, as well as enables consumers to make decisions on products and materials in regard to the associated impacts of the particular product.
Goals
Methodology
The goals of this study were to:
This study was conducted according to the life cycle inventory (LCI) and life cycle impact assessment (LCIA) standards established by the International Organization for Standardization (ISO) life cycle assessment standards ISO 14040 series. The geographic boundary for this study is primarily North America. This is a cradle-to-grave LCA study examining select vinyl rail, vinyl fence and composite rail products from raw materials extraction and processing through end of life.
• P rovide a baseline LCA in order to understand and evaluate the impacts of the Vinyl Fence, Vinyl Rail and Composite Rail across the product life cycle. • As a basis for publication in the BEES product database. • P osition CertainTeed Fence, Rail and Deck as an industry leader in product stewardship. • P repare CertainTeed for sustainable supply chain requirements, carbon taxes, and other potential policy requirements. • P rovide competitive analysis and positioning in order to analyze and evaluate claims or LCA/EPD information published in the future by competitors. • T o meet future requirements for green purchasing programs for the United States Government, corporations, or other businesses.
For this life cycle assessment, Sustainable Solutions Corporation (SSC) collected specific data on energy and material inputs, wastes, water use, emissions, and transportation impacts for the Buffalo, NY facility. Production data was allocated for these inputs in collaboration with process experts and allocated by pound of production. The National Renewable Energy Lab (NREL) US LCI database, ecoinvent database, and literature served as the sources of secondary inventory data for energy, transportation, and raw materials processes not directly collected from CertainTeed. Cumulative energy demand and the National institute of Standards and Technology (NIST) BEES 4.04+ (Building for Environmental and Economic Sustainability) factors were the methodologies selected for the life cycle impact assessment.
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Executive Summary (continued) Key Findings
Recommendations
Based on the results from the life cycle assessment, the life cycle impacts for Bufftech and Panorama impacts are driven by the installation phase; raw materials are the main driver for the Kingston railing system. The reduction in electricity impacts from the purchase of hydro-electric energy reduces the overall impacts of global warming, acidification, criteria air pollutants, ecotoxicity, smog, and natural resource depletion in the manufacturing phase for all products. The composite rail has clear advantages in raw materials as the primary ingredient is recycled content obtained from product returns of composite deck product. These factors contribute to overall decreased impacts in most impact categories for the Panorama railing systems.
CertainTeed should use the results of this life cycle impact assessment study for reducing impacts and product improvements including: • C ommunicate results of the LCA to R&D personnel and new product development teams. Use these LCA results as a tool during the product development cycle with the intent of evaluating lower impact ingredients, suppliers, and design. – Any way to reduce the installation materials required while maintaining product performance would be the best way to reduce environmental impacts.
• While the contract with the local hydropower facility in which CertainTeed purchases all electricity for the facility greatly reduces upstream impacts from electricity for all products, the results of this LCA can continue to evaluate energy conservation opportunities to reduce energy consumption and related impacts in the manufacturing operation. – Sub-metering electricity can help enable conservation analysis. • P roceed with the publication of the LCA data in the BEES database, which is maintained by NIST (National Institute for Standards and Technology).
• Encourage suppliers to develop life cycle inventories and implement programs to reduce their own operational environmental impacts. • Enhance installer training to encourage more efficient product installation techniques.
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Table of Contents Executive Summary............................................................ i List of Figures....................................................................iv List of Tables.......................................................................v Introduction....................................................................... 1 Background........................................................................ 1 Overview of Life Cycle Assessment.................................... 2 Goal and Scope Definition.............................................. 4–7 Goal of the Study............................................................... 4 Functional Unit................................................................... 5 System Boundary............................................................... 6 Cut-off Criteria................................................................... 7 Data Sources and Modeling Software.......................... 8–13 Data Quality........................................................................ 8 Data Sources...................................................................... 9
Impact Categories / Impact Assessment.......................... 17 Selected Impact Categories.............................................. 18 Manufacturing Process Allocation and Assumptions....... 19 Initial Service and End-of-Life Assumptions.................... 19
Heat Stabilizer.................................................................. 13
Vinyl Fence, Vinyl Rail and Composite Rail LCA Results...................................... 20–47
Modeling Software........................................................... 13
Manufacturing Impacts............................................... 20-23
Life Cycle Inventory Analysis..................................... 14–16
Raw Material Impacts................................................ 24–30
Raw Materials and Product Recipe Overview................... 14
Installation and Use Phase......................................... 31–34
Manufacturing Process Overview.................................... 15
Overall Environmental Impact ................................... 35–47
Distribution...................................................................... 16
Hydropower Sensitivity Analysis................................ 48–51
Installation....................................................................... 16
Recycled Content Sensitivity Analysis........................ 52–53
End-of-Life....................................................................... 16
Limitations....................................................................... 54
Life Cycle Impact Assessment (LCIA).............................. 17
Conclusions..................................................................... 55
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List of Figures Figure 1.1 – The Four Stages of Life Cycle Assessment..... 2 Figure 2.1 – System Boundary for Vinyl Fence, Vinyl Rail and Composite Rail........................ 6 Figure 6.1 – Life Cycle Stage Control Diagram................. 20 Figure 6.2 – Energy Distribution of the Buffalo Manufacturing Process.............................. 21 Figure 6.3 – Global Warming Potential Distribution to Manufacture Vinyl Rail and Fence Products................. 22 Figure 6.4 – Environmental Impacts (BEES Methodology) of Buffalo Production Operations (per lb Produced)........ 23
Figure 6.11 – Kingston Installation Materials (per 8ft section)............................................................... 33 Figure 6.12 – Panorama Rail Installation Materials (per 8ft section)............................................................... 34 Figure 6.13 – Cumulative Energy Demand (CED) for the Life Cycle Stages of CertainTeed Bufftech Fence Systems (MJ / 8ft)............... 36 Figure 6.14 – Cumulative Energy Demand (CED) for the Life Cycle Stages of Kingston and Panorama Railing Systems (MJ / 8ft)............................................... 36
Figure 6.5 – Relative Environmental Impacts of One lb Each of Raw Materials.......................................... 24
Figure 6.15 – Global Warming Potential (GWP) for the Life Cycle Stages of Bufftech Fence (g CO2 eq / 8ft product).................................................... 37
Figure 6.6 – Relative Environmental Impact (BEES Methodology) Distribution of Vinyl Rail/Fence Formulation ........................................... 26
Figure 6.16 – Global Warming Potential (GWP) for the Life Cycle Stages of CertainTeed Railing Systems (g CO2 eq / 8ft)...................................... 38
Figure 6.7 – Relative Environmental Impact (BEES Methodology) Distribution of Kingston Rail Formulation................................................ 27
Figure 6.17 – Environmental Impacts of Bufftech Chesterfield Vinyl Fence (BEES Impact Assessment Methodology)........................ 40
Figure 6.8 – Relative Environmental Impact (BEES Methodology) Distribution of Panorama Rail Formulation.............................................. 29
Figure 6.18 – Environmental impacts of Bufftech New Lexington Vinyl Fence (BEES Impact Assessment Methodology)........................ 42
Figure 6.9 – Bufftech Chesterfield Installation Materials (per 8ft section)............................. 31
Figure 6.19 – Overall Life Cycle Comparison of the New Lexington and Chesterfield Fence Lines............. 43
Figure 6.10 – Bufftech New Lexington Installation Materials (per 8ft section)............................. 29
Figure 6.20 – Environmental Impacts of Kingston Vinyl Railing System......................................... 45
Figure 6.21 – Environmental Impacts of Panorama Composite Rail (BEES Impact Assessment Methodology)........................ 47 Figure 7.1 – Sensitivity Analysis on the Electricity Generation Source for the FRD Manufacturing Process................................. 48 Figure 7.2 – Sensitivity Analysis on the Electricity Generation Source for the Life Cycle of the Kingston Railing System.................. 50 Figure 7.3 – Sensitivity Analysis on the Electricity Generation Source for the Life Cycle of the Panorama Railing System................ 51 Figure 7.4 – Relative Overall Life Cycle Environmental Impacts of Bufftech Chesterfield Fence with and without Recycled Content.................................. 53
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List of Tables Table 2.1 – Bufftech® Vinyl Fence Product Details............. 5
Table 6.4 – Environmental Impact (BEES Methodology) Distribution of Vinyl Rail/Fence Formulation.................... 25
Table 6.14 – Bufftech New Lexington Vinyl Fence Environmental Impacts per 8ft......................................... 41
Table 2.3 – System Boundary Description......................... 6
Table 6.5 – Environmental Impact (BEES Methodology) Distribution of Kingston Vinyl Rail Formulation (per lb)... 28
Table 6.15 – Environmental Impacts of Kingston Vinyl Railing System (per 8ft)....................... 44
Table 3.1 – Data Sources for Vinyl Fence, Vinyl Rail and Composite Rail.......................................... 10
Table 6.6 – Environmental Impact (BEES Methodology) Distribution of Panorama Rail Formulation (per lb)......... 30
Table 6.16 – Environmental Impacts of Panorama Composite Railing System (per 8ft)............ 46
Table 4.1 – Vinyl Fence (Bufftech) Product Recipe........... 14
Table 6.7 – Bufftech Chesterfield Installation Materials (per 8ft section)............................. 31
Table 7.1 – Sensitivity Analysis on the Electricity Generation Source for the FRD Manufacturing Process (per lb of Product)...................... 48
Table 2.2 – Kingston Vinyl Rail Product Details................. 5
Table 4.2 – Vinyl Rail Product Recipe.............................. 14 Table 4.3 – Composite Rail Product Recipe..................... 14 Table 4.4 – Manufacturing Process Materials and Fuels Inventory (per lb product)................................ 15 Table 4.5 – Packaging Inventory (per lb product)............ 15 Table 4.6 – Installation Materials Required for 8ft Section .................................................. 16 Table 6.1 – Energy Use and Global Warming Potential During the Manufacturing of Rail and Fence Products..... 21
Table 6.8 – Bufftech New Lexington Installation Materials (per 8ft section)............................. 32 Table 6.9 – Kingston Installation Materials (per 8ft section)............................................................... 33 Table 6.10 – Panorama Rail Installation Materials (per 8ft section)............................. 34
Table 7.2 – Sensitivity Analysis on the Electricity Generation Source for the Life Cycle of CertainTeed Railing Systems....................... 49 Table 7.3 – Overall Life Cycle Environmental Impacts of Bufftech Chesterfield Fence with and without Recycled Content.................................. 52
Table 6.11 – Cumulative Energy Demand (CED) for Vinyl Fence, Vinyl Rail and Composite Rail (MJ/8ft)................. 35
Table 6.2 – Environmental Impacts (BEES Methodology) of Buffalo Production Operations (per lb Produced)........ 23
Table 6.12 – Global Warming Potential (GWP) Values for Vinyl Fence, Vinyl Rail and Composite Rail (g CO2 eq/8ft) ......................................... 37
Table 6.3 – Environmental Impacts of One lb Each of Raw Materials.......................................... 24
Table 6.13 – Bufftech Chesterfield Vinyl Fence Environmental Impacts per 8ft......................................... 39
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Life Cycle Assessment
1.0 Introduction Life cycle assessment (LCA) is a powerful tool used to quantify the environmental impacts associated with the various stages of a product’s life. Section 1 provides a background and overview of LCA methodology and benefits.
1.1 Background The use of LCA is growing rapidly in the building products market. CertainTeed and its parent company, Saint-Gobain, has been a leader in developing sustainable and innovative products. The company is developing its product stewardship program to evaluate and reduce the impacts of products and processes throughout the corporation and business groups. This report will baseline and benchmark the Bufftech, Kingston and Panorama products to assist with measuring and understanding the environmental
impacts of vinyl fence, vinyl rail and composite rail across the life cycle. The models and data developed by conducting this LCA will assist the CertainTeed Fence, Rail and Deck (FRD) group with integrating sustainable product design processes including manufacturing improvements, alternate raw materials and raw material source locations, and other aspects to reduce environmental impacts across the life cycle for this product. This LCA is also very valuable to CertainTeed as a tool for competitive positioning, and will provide the details to CertainTeed to take a leadership role in the field of product stewardship. It can help CertainTeed lead the possible future development of an industry product category rule (PCR).
The LCA allows CertainTeed to understand and evaluate any future data or LCA published by competitors. The LCA will also prepare CertainTeed for sustainable supply chain requirements and other policy innovations. CertainTeed has submitted this inventory data to the National Institute of Standards and Technology (NIST) to be uploaded in the life cycle database, BEES (Building for Environmental and Economic Sustainability) product LCA database.
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1.2 Life Cycle Assessment Life Cycle Assessment (LCA)* is an analytical tool used to comprehensively quantify and interpret the environmental flows to and from the environment (including emissions to air, water and land, as well as the consumption of energy and other material resources) over the entire life cycle of a product (or process or service). By including the impacts throughout the product life cycle, LCA provides a comprehensive view of the environmental aspects of the product and an accurate picture of the true environmental tradeoffs in product selection.
global warming potential effects). The impact assessment phase of LCA is used to evaluate the significance of potential environmental impacts based on the LCI results. The impact assessment data is interpreted and validated by sensitivity analysis by the LCA practitioner to provide useful data to the company that commissioned the LCA.
The working procedure of LCA is iterative, as illustrated with the back-and-forth arrows in Figure 1.1. The iteration means that information gathered in a later stage can cause effects in a former stage. When this occurs, the former stage and the following stages have to be reworked, taking into account the new information. Therefore, it is common for an LCA practitioner to work at several stages at the same time.
Figure 1.1 The Four Stages of Life Cycle Assessment
The standards in the ISO 14040-series set out a four-phase methodology framework for completing an LCA, as shown in Figure 1: (1) goal and scope definition, (2) life cycle inventory (LCI), (3) life cycle impact assessment, and (4) interpretation. An LCA starts with an explicit statement of the goal and scope of the study; the functional unit; the system boundaries; the assumptions, limitations and allocation methods used; and the impact categories chosen. In the inventory analysis, a flow model of the technical system is constructed using data on inputs and outputs. The input and output data needed for the construction of the model are collected (including resources, energy requirements, emissions to air and water, and waste generation for all activities within the system boundaries). Then, the environmental loads of the system are calculated and related to the functional unit, to finalize the flow model. Inventory analysis is followed by impact assessment, where the LCI data are characterized in terms of their potential environmental impact (e.g., acidification, eutrophication and
* This introduction is based on international standards in the ISO-14040 series, Environmental Management – Life Cycle Assessment.
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1.2 Life Cycle Assessment (continued) This LCA study is characterized as a “cradle-to-grave” study, examining vinyl fence, vinyl rail and composite rail systems from raw material extraction through final disposal. For this life cycle assessment, Sustainable Solutions Corporation (SSC) collected specific data on energy and material inputs, wastes, water use, emissions, and transportation impacts for the specified products based on production in Buffalo, NY for the calendar year 2013. This LCA was conducted using SimaPro software with the National Renewable Energy Lab (NREL) US LCI database serving as the primary source of life cycle inventory data for raw materials and processes not directly collected from Buffalo, NY. Where data was not available in the US LCI database, data from the ecoinvent LCI database, private SSC LCI databases, and published reports were used. Data from European databases was adapted using US electricity impacts. The BEES+ 4.04 impact assessment methodology was used to calculate the environmental impacts in this LCA. BEES was developed
by the National Institute of Standards and Technology (NIST) as a tool to assist in impact analysis in Life Cycle Assessments, process design, and pollution prevention. Impact categories include: 1. Global Warming Potential
Potential benefits of a life cycle assessment include: better materials sourcing, manufacturing process environmental impact reduction, education, evaluation of raw materials, impacts to product standards, decreased air emissions, waste reduction, increased recycling, reduced water use, and cost savings, among many others.
2. Acidification 3. Human Health 4. Criteria Air Pollutants 5. Eutrophication 6. Smog 7. Fossil Fuel Depletion 8. Indoor Air Quality 9. Habitat Alteration 10. Ozone Depletion
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2.0 Goal and Scope Definition The nature of life cycle assessment is to include a wide range of inputs associated with the product being analyzed. Constraining the LCA scope is an essential part of the study. The following section defines the goal, scope, and boundaries of this LCA study.
2.1 Goal of the Study The goal of this analysis is to identify and quantify the environmental impacts associated with each stage in the life cycle of the vinyl fence, vinyl rail and composite rail products, including raw material extraction, processing, and shipping; manufacturing; final product shipping; product use; and end-of-life disposition. Intended Uses LCA is a tool that can effectively be applied for manufacturing process improvements, education and market support, environmental management, and sustainable reporting. CertainTeed, who is the primary audience of the study, intends to use the study results mainly for the following purposes: • Provide a baseline LCA in order to understand and evaluate the impacts of the Vinyl Fence, Vinyl Rail and Composite Rail across the product life cycle.
• Product Stewardship – LCA is a tool in the CertainTeed Fence, Rail and Deck product stewardship program. This LCA will be used by the CertainTeed Fence, Rail and Deck new product development team members to quantify and understand the impacts of the products and processes throughout the life cycle in order to integrate sustainable product design techniques to reduce the impacts, to the extent possible.
• P rovide competitive analysis and positioning in order to analyze and evaluate claims or LCA / EPD information published in the future by competitors.
• Process Improvements and New Technology Evaluation
• T o meet future requirements for green purchasing programs for the United States Government, corporations, or other businesses.
– CertainTeed FRD can use the completed LCA to evaluate possible process improvements in the manufacture of fence and railing products produced at CertainTeed facilities. Based on the results, they can evaluate alternate ingredients or raw materials, opportunities for integration of recycled content or bio based materials, and opportunities for designing a closed loop product in the future.
• As a basis for publication in the BEES product database. • A s a tool to illustrate the reduced environmental impacts to regulatory agencies such as the U.S. EPA of process, facility or raw material improvements.
• P osition CertainTeed Fence, Rail and Deck as an industry leader in product stewardship. • P repare CertainTeed for sustainable supply chain requirements, carbon taxes, and other potential policy requirements.
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2.2 Functional Unit All flows to and from the environment within the system boundary (see Section 2.3) are normalized to a unit summarizing the function of the system. The function of fence is to provide privacy and security along property perimeters. Railings provide safety and aesthetics along the edge of decks, porches, stairs and other areas. Once the primary functions of the systems are defined, a functional unit is selected in order to provide a similar basis, consistent with the above mentioned goals, for summarizing the LCA. The functional unit utilized for this study is an eight feet (8ft.) section of fence or railing with a service life of 25 years for railing systems and 50 years for fencing systems, including end-of-life disposition. This functional unit is consistent with the goal and scope of the study. Tables 2.1-2.2 list specific details of the Bufftech®, Kingston, and Panorama® products which are representative products of the product lines produced in Buffalo for vinyl fence, vinyl rail and composite rail, respectively. The functional unit determines the environmental impacts and is the basis for comparison in an LCA. It provides a unit of analysis and comparison for all environmental impacts.
Table 2.1 Bufftech ® Vinyl Fence Product Details
Bufftech® Vinyl Fence Chesterfield
New Lexington
Buffalo, NY
Buffalo, NY
8ft
8ft
Weight
70.48 lb
52.82 lb
Lifetime
50 years
50 years
Privacy and Aesthetics
Privacy and Aesthetics
Manufacturing Location Functional Unit
Product Function
Table 2.2 Kingston Vinyl Rail Product Details
Kingston Vinyl Railing System
Panorama Composite Railing System
Buffalo, NY
Buffalo, NY
8ft
8ft
Weight
28.69 lb
44.01 lb
Lifetime
25 years
25 years
Aesthetics and Safety
Aesthetics and Safety
Manufacturing Location Functional Unit
Product Function
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2.3 System Boundary This project considers the life cycle activities from resource extraction through product use for a 25 year life cycle inclusive of maintenance and end-of-life effects. Maintenance during the product’s use phase includes occasional cleaning with soapy water; as the cleaning frequency is variable and often not executed in real world practice, this was excluded from the scope of this study. Figure 2.1 defines the system boundary for this study. The study system boundary includes the transportation of major inputs to (and within) each activity stage including the shipment of final products to the use site, based on logistics data provided by CertainTeed by common modes, as well as transportation to a landfill at the end of the service life. Any site-generated energy and purchased electricity is included in the system boundary. The extraction, processing and delivery of purchased primary fuels, e.g., propane and primary fuels used to generate purchased electricity, are also included within the boundaries of the system. Purchased electricity consumed at the Buffalo site location is modeled using hydropower generation, based on the power purchase agreement between the electricity provider and CertainTeed.
Both human activity and capital equipment were excluded from the system boundary. The environmental effects of manufacturing and installing capital equipment and buildings have generally been shown to be minor relative to the throughput of materials and components over the useful lives of the buildings and equipment. Human activity involved in the manufacture of fencing and rail products and their component materials no doubt has a burden on the environment; however, the data collection required to properly quantify human involvement is
particularly complicated, and allocating such flows to the production of these products, as opposed to other societal activities, was not feasible for a study of this nature. Typically, human activity is only considered within the system boundary when value-added judgments or substituting capital for labor decisions are considered to be within the scope of the study; however, these types of decisions are outside this study’s goal and scope. The details of the data excluded from the system boundary can be found in the subsequent inventory sections.
Figure 2.1 System Boundary for Vinyl Fence, Vinyl Rail and Composite Rail
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2.3 System Boundary (continued) Table 2.3 System Boundary Description
Included
Excluded
Raw material acquisition and processing
Construction of capital equipment
Processing of materials
Maintenance of operation and support equipment
Transport of raw materials
Human labor and employee commute
Energy used in production (lighting, heating, cooling, etc.) Occasional cleaning during use at manufacturing facilities Energy required for installation Interplant and final product shipping Accessory materials such as gates and post lights Packaging Manufacturing waste and emissions Installation materials Product disposal 2.3.1 Cut-off Criteria Processes whose total contribution to the final result, with respect to their mass and in relation to all considered impact categories, is less than 1% can be neglected. The sum of the neglected processes may not exceed 5% by mass and by 5% of the considered impact categories. For that a documented assumption is admissible. For Hazardous Substances, as defined by the U.S. Occupational Health and Safety Act, the following requirements apply: • T he Life Cycle Inventory (LCI) of hazardous substances will be included, if the inventory is available.
• If the LCI for a hazardous substance is not available, the substance will appear as an input in the LCI of the product, if its mass represents more than 0.1% of the product composition. • If the LCI of a hazardous substance is approximated by modeling another substance, documentation will be provided. This LCA is in compliance with the cut-off criteria since only potential installation energy was neglected or excluded from this analysis outside of the specific items listed under “Excluded” in Table 2.3. For the disposal phase, the product was modeled as materials sent to landfill, as this is the most common way of dealing with these products at the end-of-life.
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3.0 Data Sources and Modeling Software The quality results of an LCA study are directly dependent on the quality of input data used in the model. This section describes the data quality guidelines used in this study, the sources from which the data was selected, the software used to model the environmental impacts, and any data excluded from the scope of the study.
3.1 Data Quality Wherever secondary data is used, the study adopts critically reviewed data for consistency, precision, and reproducibility to limit uncertainty. The data sources used are complete and representative of North America in terms of the geographic and technological coverage and are a recent vintage (i.e. less than ten years old). Any deviations from these initial data quality requirements for secondary data are documented in the report. The results of an LCA are only as good as the quality of input data used. Important data quality factors include precision (measured, calculated or estimated), completeness (e.g., unreported emissions or excluded flows), consistency (uniformity of the applied methodology throughout the study), and reproducibility (ability for another researcher reproduce the results based on the methodological information provided). The primary data from the manufacturer was from the latest data available. Each dataset used was taken from SimaPro databases, either US LCI or ecoinvent. These databases are widely distributed and referenced within the LCA community and are either partially or fully critically reviewed.
Precision
Completeness
The data used for primary data are based on direct information sources of the manufacturer. The energy and water usage data was collected directly from the utility meters, and the allocation was based on production at the plant. Therefore the precision for primary data is considered high; however, the uncertainty of the primary data has not been quantified.
The processes modeled represent the specific situations in vinyl fence, vinyl rail and composite rail life cycles. System boundaries and exclusions are clearly defined in the sections above, and no other data gaps were identified.
Secondary data sets were used for raw materials extraction and processing, end of life, transportation, and energy production flows. The US ecoinvent database was used for most of the raw material data sets. Since the inventory flows for ecoinvent processes are very often accompanied by a series of data quality ratings, a general indication of precision can be inferred. Using these ratings, the data sets used generally have mediumto-high precision. Precision for the datasets used from the US LCI database was not formally quantified. However, many data sets from the US LCI were developed based on well-documented industry averages with data quality indicators provided for each flow.
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3.1 Data Quality (continued) Consistency Primary data was collected from the CertainTeed FRD experts as tracked by World Class Manufacturing automated systems and records. Since most of the data is annually reported, the consistency is considered high. Secondary data was consistently modeled using either US LCI or ecoinvent databases as available. Proxies were only identified and used if secondary data was not available in these or other databases. This methodology provides consistency throughout the model. Reproducibility Most datasets are from nationally accepted and publicly available databases, ensuring reproducibility by an average practitioner. Confidential data from the plant would inhibit reproducing these results without access to the data.
The primary data from the manufacturer was from the latest data available, incorporating the most recent updates to the process into the model. Each dataset used was taken from SimaPro databases, either US LCI or ecoinvent. These databases are widely distributed and referenced within the LCA community. The datasets use relevant yearly averages of primary industry data or primary information sources of the manufacturer and technologies. The uncertainty of each dataset is not formally quantitatively known. Each dataset is from publicly available databases, ensuring reproducibility. The representativeness of the datasets is chosen to be representative of North America, average technologies of the major producers and distributors and of recent and modern vintage. Below is a more detailed description of the datasets used in the model of raw materials extraction and processing for the major components of vinyl fence, vinyl rail and composite rail.
Representativeness The representativeness of the datasets is chosen to be representative of North America, average technologies of the major producers and distributors and of recent and modern vintage. Uncertainty Most of the secondary data sets in US LCI and ecoinvent databases have some uncertainty information documented and varies per model. Uncertainty for primary data was not quantified. However, the collected data and allocation methodologies were judged by the operations personnel to be accurate, so the uncertainty is considered low.
3.2 Data Sources North America is considered as the geographic boundary of this study. The reference year is 2013 since the primary CertainTeed Vinyl Fence, Vinyl Rail and Composite Rail manufacturing data were gathered for that calendar year. Both primary and secondary LCI and metadata are used throughout the study. All secondary data is taken from literature, previous LCI studies, and life cycle databases. The US LCI database (www.nrel.gov/lci) is frequently used in this analysis. Much of the LCI data residing in the US LCI database pertain to common fuels – their combustion
in utility, stationary and mobile equipment inclusive of upstream or pre-combustion effects (i.e. back to earth). Generally, these modular data are of a recent vintage (less than ten years old). This study draws on these data for combustion processes, electricity generation, and transportation on a regional North American basis. These data are free and publicly available, and thus, offer both a high degree of transparency and an ability to replicate the results of the study; however, there are limitations, as some processes are missing for some of the products available in this LCI database, creating an issue with respect to completeness. When North American data was not available for a product or process, the European ecoinvent LCI database was utilized. This database contains over 3,500 LCI modules for processes and products, all of which have undergone peer review. The basic assumption when using these data is that North American and European production processes are generally similar, but that these data need to be adapted for North American circumstances (e.g., electricity grids, fuels and transportation modes and distances need to be modified to better reflect the North American operations). Such adaptation was conducted whenever necessary.
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3.2 Data Sources (continued) Table 3.1 Data Sources for Vinyl Fence, Vinyl Rail and Composite Rail
Material Input
Database(s) and Source
Temporal Information
Regional Coverage
Technology Coverage
Data Type
Wood/PVC Regrind Composite (Panorama only)
Proxy – Assumed cut-off methodology for recycled material; processing energy based on specific data from Return Polymers
2011
North America
Supplier specific
Primary
Calcium Carbonate
US LCI – as Limestone
2008
United States
Quarried from open pits by blasting, followed by mechanical crushing and screening
Secondary
External PVC Regrind
Proxy – Assumed cut-off methodology for recycled material; processing energy based on specific data from Return Polymers
2011
North America
Supplier specific
Primary
Calcium Stearate
Quicklime – US LCI, Fatty acids, ecoinvent
2000s Data
North America and Europe, adapted to US Conditions via EarthShift
Most recent technology
Secondary
Impact Modifier – Arkema
91% polymethyl methacrylate (proxy for “proprietary acrylate polymer”), 5% Calcium carbonate, 5% ethoxylated alcohol (proxy for surfactact)
2008
North America and Europe, adapted to US Conditions via EarthShift
Mix of technologies for proxy
Proxy
Impact Modifier
Acrylic filler, ecoinvent; Methyl methacrylate, ecoinvent
2000s Data
Europe, adapted to North American conditions via EarthShift
50% Acrylic filler, 50% MMA
Secondary
Oxidized Polyethylene
Paraffins, ecoinvent and Polyethylene, US LCI
2000s Data
North America and Europe, adapted to US Conditions via EarthShift
Supplier Specific
Secondary
Paraffin
Paraffins, ecoinvent
2000s Data
Europe, adapted to North American conditions via EarthShift
Average technologies
Secondary
Polyethylene Wax
Paraffins, ecoinvent and Polyethylene, US LCI
2000s Data
North America and Europe, adapted to US Conditions via EarthShift
Supplier specific
Secondary
PVC Resin
Previous LCA Study from Lake Charles Facility
2012
Facility specific
Facility specific
Primary
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3.2 Data Sources (continued) Table 3.1 Data Sources for Vinyl Fence, Vinyl Rail and Composite Rail (continued)
Material Input
Database(s) and Source
Temporal Information
Regional Coverage
Technology Coverage
Data Type
Tin Heat Stabilizer
Proxy developed from processes in ecoinvent – see Section 3.2.2
2000s Data
Europe, adapted to North American conditions via EarthShift
see Section 3.2.2
Secondary
Titanium Dioxide
Titanium dioxide, ecoinvent
2000s Data
Europe, adapted to North American conditions via EarthShift
50% sulfate process and 50% chloride process
Secondary
Regional Coverage
Technology Coverage
Data Type
Process Input
Database(s) and Source
Temporal Information
Electricity, hydropower, at plant
ecoinvent v2.2
2007
Europe, adapted to North American conditions via EarthShift
Mix of multiple hydropower generation technologies
Secondary
Propane
US LCI
2008
US average
Combustion of liquefied petroleum gas and average emissions
Secondary
Water
Tap water, ecoinvent v3
2007
Europe, adapted to rest of the World conditions
Water treatment and transportation to end user
Secondary
STABROM 909
Proxy – biocide, ecoinvent v2.2
2013
Europe, adapted to North American conditions via EarthShift
Average of multiple biocides
Proxy
Stabrex ST70
Proxy – biocide, ecoinvent v2.2
2013
Europe, adapted to North American conditions via EarthShift
Average of multiple biocides
Proxy
Corrosion Inhibitor
Proxy – Solution corrosion inhibitor ecoinvent v2.2
2013
Europe, adapted to North American conditions via EarthShift
Average of multiple solution corrosion inhibitors
Proxy
Trasar Trac101
30% sodium nitrate, 50% molybdenite, 20% water, ecoinvent v3
2013
European, adapted for Average of multiple Rest of World conditions solution corrosion inhibitors
Proxy
CL7200
Proxy – Trasar Trac101
2013
European, adapted for Average of multiple Rest of World conditions solution corrosion inhibitors
Proxy
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3.2 Data Sources (continued) Table 3.1 Data Sources for Vinyl Fence, Vinyl Rail and Composite Rail (continued)
Installation Materials
Database(s) and Source
Temporal Information
Regional Coverage
Technology Coverage
Data Type
Aluminum Inserts
Aluminum, secondary – US LCI
2008
US average
National average
Secondary
Concrete Footing
Proxy – Concrete Block, ecoinvent v3
2013
Europe, adapted to Global conditions via EarthShift
Normal concrete poured into a mold and air-dried
Secondary
Post Caps
PVC Product Formulation
2013
Facility specific
Extrusion
Secondary
Hardware
Stainless steel, ecoinvent v2.2
2007
Europe, adapted to North American conditions via EarthShift
European technology mix
Secondary
Kits
PVC Product Formulation
2013
Facility specific
Extrusion
Secondary
Steel Inserts
Stainless steel, ecoinvent v2.2
2007
Europe, adapted to North American conditions via EarthShift
European technology mix
Secondary
End of Life Waste treatment to sanitary landfill
Database(s) and Source US – ecoinvent v3
Temporal Information 2000
Regional Coverage
Technology Coverage
Data Type
European – adapted to US Conditions
Waste-specific short-term emissions to air via landfill gas incineration and landfill leachate. Burdens from treatment of shortterm leachate (0-100a) in wastewater treatment plant (including WWTP sludge disposal in municipal incinerator). Long-term emissions from landfill to groundwater (after base lining failure).
Secondary
Database(s) and Source
Temporal Information
Regional Coverage
Technology Coverage
Data Type
Truck Freight
US LCI
2000s Data
North America
Average Technologies
Primary
Rail Freight
US LCI
2000s Data
North America
Average Technologies
Primary
Ocean Freighter
US LCI
2000s Data
North America
Average Technologies
Primary
Transportation
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3.2 Data Sources (continued) 3.2.1 Heat Stabilizer An expert in PVC heat stabilizers, Rob Martin, was contacted from Dow Chemical to discuss a valid proxy to model this component. Based on his comments, the heat stabilizer model uses 9.5% tin for methyltin mercaptoester sulfides which constitute around 60% of the heat stabilizer. Additionally, between 1% and 5% mercaptoester are used in the heat stabilizer and around 25% of mercaptoethyltallate or mercaptoethanol are varied according to market price. As proxies for the mercaptan materials, materials used in the model include 11.3% chlorine (estimate based on production process of akyltin mercaptoester sulfide), 7.7% magnesium (estimate based on production process of akyltin mercaptoester sulfide, 33.5% fatty acids (estimate based on production process of akyltin mercaptoester sulfide), 1.3% hydrogen sulfide (1:1 molar ratio with ethylene oxide for proxy of mercaptoethanol), 1.7% ethylene oxide (1:1 molar ratio with hydrogen sulfide for proxy of mercaptoethanol) †, 17.5% fatty acids (proxy for mercaptoethyltallate), 17.5% fatty acids (proxy for mercaptoethyloleate).
3.3 Modeling Software SimaPro v8.0 software was utilized for modeling the complete cradle-to-grave LCI for vinyl fence, vinyl rail and composite rail. All process data including inputs (raw materials, energy and water) and outputs (emissions, waste water, solid waste, and final products) are evaluated and modeled to represent each process that contributes to the life cycle of the vinyl fence, vinyl rail and composite rail products. The study’s geographical and technological coverage has been limited to North America, focusing on the region around Buffalo, NY where applicable. SimaPro was used to generate life cycle impact assessment (LCIA) results utilizing the BEES impact assessment methodology as well as single flow environmental scores (Global Warming Potential and Cumulative Energy Demand). See Section 5.2 for a description of the selected LCIA categories and characterization measures used in this study.
† Knight, J.J.“2-Mercaptoethanol in Encyclopedia of Reagents for Organic Synthesis (Ed: L. Paquette) 2004.
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4.0 Life Cycle Inventory Analysis This section describes the cradle-to-grave life cycle inventory of vinyl fence, vinyl rail and composite rail. Primary manufacturing data was collected from surveys completed by personnel from the manufacturing plant located in Buffalo, NY for the 2013 calendar production year. The participating manufacturing plant provided resource transportation mode and distance data to support the calculation of raw material transportation flows. The transportation LCI data from the US LCI database (kg-km basis) were used to develop the resource transportation LCI profile.
4.1 Raw Materials and Product Recipe Overview A thorough analysis of the material inputs and the product recipe was completed for the inventory of this study. The vinyl fence, vinyl rail and composite rail product recipes are listed in Table 4.1 through Table 4.3.
Table 4.1 Vinyl Fence (Bufftech®) Product Recipe
Chesterfield lbs / 8ft
New Lexington lbs / 8ft
PVC resin
38.41
28.79
Titanium dioxide
1.13
0.85
Polyethylene wax
0.14
0.11
Calcium stearate
0.56
0.42
Paraffin
0.78
0.58
Stabilizer
0.49
0.37
Impact modifier (Elkem)
0.39
0.30
Impact modifier (Arkema)
0.85
0.63
Calcium carbonate
5.22
3.91
External regrind
22.55
16.90
Bufftech® Recipe
Table 4.2 Vinyl Rail Product Recipe
Kingston Recipe
Table 4.3 Composite Rail Product Recipe
Kingston lbs / 8ft
PVC resin
15.63
Titanium dioxide
0.46
Polyethylene wax
0.05
Calcium stearate
0.23
Paraffin
0.32
Stabilizer
0.20
Impact modifier (Elkem)
0.34
Impact modifier (Arkema)
0.16
Calcium carbonate
2.12
External regrind
9.18
Panorama® Recipe
Panorama® lbs / 8ft
Wood/Plastic Composite Regrind
39.61
PVC
3.61
Titanium dioxide
0.35
Polyethylene wax
0.01
Calcium stearate
0.04
Paraffin
0.05
Stabilizer
0.04
Impact modifier (Arkema)
0.11
Calcium carbonate
0.19
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4.2 Manufacturing Process Overview A detailed analysis of the manufacturing process was completed by Sustainable Solutions Corporation, including a site visit on June 3, 2014 to Buffalo, NY to observe and understand the manufacturing process.
Table 4.4 Manufacturing Process Materials and Fuels Inventory (per lb product)
Energy Inputs
Quantity
Unit
Electricity
4.55E-01
kWh
The Buffalo plant is the only CertainTeed location that produces vinyl fence, vinyl rail and composite rail for CertainTeed. The Buffalo plant produces a variety of FRD products with differing impacts, so allocation was conducted based on run hours and production per hour. Overhead energy and water consumption was included in the allocation.
Propane
1.31E-02
kWh
Quantity
Unit
Water inflow
1.68E-01
gal
Water outflow
6.82E-02
gal
Quantity
Unit
To produce fencing and railing systems, energy, water and materials go into the process and waste and emissions are outputs from the manufacturing process. An inventory was conducted and, based on the allocation described above, Table 4.4 details the process inputs and outputs and Table 4.5 details how the products are packaged.
Pulverized ASA/ AES (recycled)
5.86E-02
lbs
Waste to energy
1.36E-02
lbs
Hazardous waste
8.65E-05
lbs
Water
Waste
Table 4.5 Packaging Inventory (per lb product)
Packaging
Panorama®
Kingston
Bufftech®
Unit
Pallets
5.53E-02
5.53E-02
5.53E-02
lb packaging / lb produced
Cut to size lumber
2.31E-01
2.31E-01
–
lb packaging / lb produced
8ft lumber
7.24E-02
7.24E-02
–
lb packaging / lb produced
Cardboard slip sheet
4.18E-03
4.18E-03
4.18E-03
lb packaging / lb produced
White film
1.83E-02
1.83E-02
–
lb packaging / lb produced
Clear film
1.60E-02
1.60E-02
9.85E-03
lb packaging / lb produced
Green strapping
1.48E-03
1.48E-03
1.48E-03
lb packaging / lb produced
Boxes
3.83E-03
7.16E-03
–
lb packaging / lb produced
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4.3 Distribution Final products were modeled as being shipped 717 miles by truck for distribution.
4.4 Installation The installation of fence and railing systems require additional materials per section of fence/rail. As any energy required from power tools to install the products are significantly smaller than energy required to manufacture the products and meets the cut-off criteria, this energy was excluded. The required installation materials are detailed in Table 4.6. During the use phase, the products may be cleaned with soapy water; however, this was excluded from the scope.
4.5 End of Life
Table 4.6 Installation Materials Required for 8ft Section
Bufftech® Chesterfield Fence
Bufftech® New Lexington Fence
Kingston Railing System
Panorama® Railing System
Unit
CertainTeed section
70.48
52.82
28.69
44.01
lbs
Posts and post caps (including 2 posts)
17.57
14.52
9.53
11.01
lbs
Hardware
3.92
3.92
–
3.76
lbs
Steel insert
5.94
6.42
–
–
lbs
Aluminum insert (90% recycled content)
–
–
6.8
–
lbs
Bracket kit
–
–
0.97
–
lbs
100
100
–
–
lbs
–
–
–
2.09
lbs
Installation Material
Concrete footing Miscellaneous
An average of 25 years is suggested as the likely life of most vinyl Rail and composite rail products. Lifetime warranties are provided by CertainTeed for fence products, so a lifetime of 50 years can be assumed for vinyl fence. The products’ end-of-life assumed to be inert in a landfill. This gate-tograve flow data were combined with resource extraction and processing data.
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5.0 Life Cycle Impact Assessment (LCIA) The environmental impacts of a product can be categorized and presented in many ways. This section briefly describes the methodology used to develop the impact assessment and defines the selected impact categories used to present the results. This section also lists assumptions of the study and describes the inherent limitations and uncertainty of the LCA results.
5.1 Impact Categories / Impact Assessment As defined in ISO 14040:2006, “the impact assessment phase of an LCA is aimed at evaluating the significance of potential impacts using the results of the LCI analysis”. In the LCIA phase, SSC modeled a set of selected environmental issues referred to as impact categories and used category indicators to aggregate similar resource usage and emissions to explain and summarize LCI results data. These category indicators are intended to “characterize” the relevant environmental flows for each environmental issue category to represent the potential or possible environmental impacts of a product system. ISO 14044 does not specify any specific methodology or support the underlying value choices used to group the impact categories. The value-choices and judgments within the grouping procedures are the sole responsibilities of the commissioner of the study.
The framework surrounding LCIA includes three steps that convert LCI results to category indicator results. These include the following: 1. Selection of impact categories, category indicators and models. 2. Assignment of the LCI results to the impact categories (classification) – the identification of individual inventory flow results contributing to each selected impact indictor. 3. Calculation of category indicator results (characterization) – the actual calculation of the potential or possible impact of a set of inventory flows identified in the previous classification step. To maximize the reliability and flexibility of the results, SSC used an established impact methodology for assigning and calculating impacts. The Building for Environmental and Economic Sustainability (BEES) methodology was used for all calculations of environmental impact. BEES was developed by the National Institute of Standards and Technology (NIST) to assist in impact analysis in Life Cycle Assessments, process design, and pollution prevention.
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5.2 Selected Impact Categories While LCI practice holds to a consistent methodology, the LCIA phase is an evolving science and there is no overall generally accepted methodology for calculating all of the impact categories that might be included in an LCIA. Typically, the LCIA is completed in isolation of the LCI. The LCI involves the collection of a complete mass and energy balance for each unit process under consideration. Once completed, the LCI flows are sifted through various possible LCIA indicator methods and categories to determine possible impacts. Due to the North American focus of this LCA study, the BEES+ 4.04 LCIA methodology was used to characterize the study’s LCI flows. Impact categories include:
3. Human Health: Cancer & Non-cancer (g C6H6 eq + g C7H7 eq) – This impact assesses the potential health impacts of more than 200 chemicals. These health impacts are general, based on emissions from the various life cycle stages, and do not take into account increased exposure that may take place in manufacturing facilities. In measuring the potential contribution to cancer, the Toxic Equivalency Potential for each chemical is determined and is displayed in terms of benzene equivalents. In measuring contribution to health impacts other than cancer, the Toxic Equivalency Potential for each chemical is determined and is displayed in terms of toluene equivalents.
1. Global Warming Potential (g CO2 eq) – Carbon dioxide and other greenhouse gasses are emitted whenever fossil fuels are burned and from a number of other human activities. These gasses can trap heat close to the Earth, contributing to global warming. A general increase in temperature can alter atmospheric and oceanic temperatures, which can potentially lead to alteration of ocean currents and weather patterns, as well as rising sea levels. The global warming potential of an activity emission is calculated on the basis of the grams of carbon dioxide equivalents.
4. Criteria Air Pollutants (microDALYS) – These are commonly found air pollutants. They include particle pollution (often referred to as particulate matter), ground-level ozone, carbon monoxide, sulfur oxides, nitrogen oxides, and lead. These pollutants can cause harm to human health and the environment. This impact measures the amounts of the criteria air pollutants: nitrogen oxides, sulfur oxides, and particulate matter. Lead, ground level ozone, and carbon monoxide are captured in other impacts.
2. Acidification (H+ moles eq) – Acidification is a more regional, rather than global impact, affecting fresh water and forests as well as human health when high concentrations of sulfur and nitrogen compounds are attained. Acidification can kill trees and make water and soil less able to support plant and animal life. The acidification potential of an air emission is calculated on the basis of the number of H+ ions that can be produced and, therefore, is expressed as potential H+ equivalents on a mass basis.
5. Eutrophication (g N eq) – Eutrophication is the fertilization of surface waters by nutrients that were previously scarce. When a previously scarce or limiting nutrient is added to a water body, it leads to the proliferation of aquatic photosynthetic plant life. This may lead to the water body becoming hypoxic, eventually causing the death of fish and other aquatic life. This impact is expressed on an equivalent mass of nitrogen (N) basis.
6. Ecotoxicity (g 2,4-D eq) – The ecological toxicity impact measures the potential of a chemical released into the environment to harm terrestrial and aquatic ecosystems. This potential is measured in terms of 2,4-dichlorophenoxy-acetic acid (2,4-D) equivalents. 7. Smog (g NOx eq) – Under certain climatic conditions, air emissions from industry and transportation can be trapped at ground level where, in the presence of sunlight, they produce photochemical smog, a symptom of photochemical ozone creation potential (POCP). While ozone is not emitted directly, it is a product of interactions of volatile organic compounds (VOCs) and nitrogen oxides (NOx). The Smog indicator is expressed as a mass of equivalent NOx. 8. Natural Resource Depletion (MJ surplus) – This impact measures the use of extracted fossil fuels (petroleum, coal, and natural gas). 9. Indoor Air Quality (kg TVOC eq) – It measures the effects of products on the air quality inside buildings, primarily through the measurement of volatile organic compound (VOC) emissions. As no indoor air emissions are tracked through CertainTeed or their suppliers, this impact category was removed from the analysis. 10. Habitat Alteration (T&E Count) – This impact measures the potential for land use by humans to lead to damage of Threatened and Endangered Species. In BEES, habitat alteration is assessed based on the amount of waste sent to landfill through the life of the product and at the point of final disposal.
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5.2 Selected Impact Categories (continued) 11. Ozone Depletion (g CFC-11 eq) – Certain chemicals, when released into the atmosphere, can cause depletion of the ozone layer, which protects the Earth and its inhabitants from certain types of harmful radiation. This impact measures the releases of those chemicals in terms of CFC-11 equivalents. Primary energy use on a cumulative energy demand basis is tabulated and summarized as an impact category directly from the LCI flow results. Energy use is a key impact indicator over which manufacturers are likely to assert a considerable level of control and, therefore, is a good internal target for resource conservation. Cumulative energy demand is the sum of all energy sources drawn directly from the earth, such as natural gas, oil, coal, biomass, or hydropower energy. The total primary energy contains further categories, namely non-renewable and renewable energy, and feedstock energy.
5.3 Manufacturing Process Allocation and Assumptions
5.4 Initial Service and End-of-Life Assumptions
Life cycle analysis requires that assumptions are made to constrain the project boundary or model processes when little to no data is available. In this study of fencing and railing products, the following assumptions were made:
The study assumes the service life is 25 years for railing systems and 50 years for fencing products; the end-of-life disposition is modeled as landfilled. The selected service life used in the project reflects the expert opinions of the product manufacturers. Disposal in a municipal landfill or in commercial incineration facilities is permissible and should be done in accordance with local, state, and federal regulations.
• Solid waste is sent for waste-to-energy. • W hen a material is not available in the available LCI databases, another chemical which has similar manufacturing and environmental impacts may be used as a proxy, representing the actual chemical. The Proxy Chemical List used in this analysis includes: – Composite decking: • The wood/plastic composite regrind decking material was assumed the raw material extraction is burden-free due to the cut-off methodology • Regrind energy submitted from Return Polymers was assumed to be equivalent for processing of this material. – Heat Stabilizer: 9.5% tin, 11.3% chlorine, 7.7% magnesium, 33.5% fatty acids, 1.3% hydrogen sulfide, 1.7% ethylene oxide, 35% fatty acids. – Calcium Stearate: 9% Quicklime and 91% fatty acids. – Water Treatment Chemicals: If no water treatment chemical was available to match the MSDS of the manufacturing facility, the ecoinvent biocide process was used as a proxy. See Table 3.2 for more details. – Oxidized Polyethylene: high density polyethylene resin.
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6.0 Vinyl Fence, Vinyl Rail and Composite Rail LCA Results This section presents the results of the LCA study. It includes energy, global warming, and other quantified impacts for each of the BEES impact categories.
6.1 Manufacturing Impacts
Figure 6.1 Life Cycle Stage Control Diagram
A manufacturer chooses the raw materials and processes that will be used to produce a product, but their ability to directly influence the processing, and thus environmental impact, of raw materials is typically outside of the manufacturer’s control. Figure 6.1 – Life cycle stage control diagram below illustrates the total life cycle of a product from raw materials extraction and processing through installation, use and end-of-life. Environmental impacts that occur in raw material shipping, manufacturing, and final product shipping are directly under CertainTeed Fence, Rail and Deck’s control. This puts much of the environmental impact of the final product out of the control of CertainTeed Fence, Rail and Deck, unless material substitutions can be made.
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6.1 Manufacturing Impacts (continued) 6.1.1 Manufacturing Energy and Carbon Analysis
Table 6.1 Energy Use and Global Warming Potential During the Manufacturing of Rail and Fence Products
Energy is required to extract, process, and ship raw materials to the plant, manufacture the product and ship the final product to the customer. Table 6.1 lists the amount of cumulative energy consumed for the manufacturing process, those processes most directly under the control of CertainTeed. All of the energy consumption was converted to megajoules (MJ) to allow for comparison of energy consumption across all uses. This energy consumption is based on the original manufacturing inventory in Section 4.2 where allocation and fuels and energy sources are discussed. Figure 6.2 and Figure 6.3 show the same distribution in pie charts. This further illustrates the overwhelming contribution that electricity consumption contributes to energy consumed to produce fence, rail and deck products in Buffalo.
Cumulative Energy Demand
Global Warming Potential
MJ / lb
gCO2 / lb
Electricity
1.7E+00
2.7E+00
Propane
2.7E-03
4.3E-02
Water
8.6E-03
6.0E-01
Waste and Scrap
1.4E-02
2.2E+0
Fuel / Ancillary Material Transport
4.9E-02
3.5E+00
Total
1.8E+00
9.9E+00
Figure 6.2 Energy Distribution of the Buffalo Manufacturing Process
While electricity is the largest energy consumer at the facility for the process, the Buffalo facility has a power purchase agreement between the local hydropower generator. Based on this agreement, the electricity provided to the facility is 100% hydropower generated and therefore has less upstream energy consumption impacts compared to the average electricity grid. A sensitivity analysis on the electricity mix is further investigated in Section 7.
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6.1 Manufacturing Impacts (continued) 6.1.1 Manufacturing Energy and Carbon Analysis (continued)
Figure 6.3 Global Warming Potential Distribution to Manufacture Vinyl Rail and Fence Products
While electricity is the largest driver of cumulative energy demand, waste disposal is the largest driver of global warming impacts for manufacturing fence, rail and deck products. As the Buffalo facility sends solid waste to a waste-to-energy facility, the carbon emissions from the incineration of the waste drives the manufacturing carbon footprint. 6.1.2 Additional Environmental Impacts from Manufacturing Besides energy demand and carbon emissions, manufacturing impacts other impacts as well. A BEES analysis was run for the manufacturing phase. Figure 6.2 shows the overall trends of the manufacturing phase at the Buffalo plant.
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6.1 Manufacturing Impacts (continued) 6.1.2 Additional Environmental Impacts from Manufacturing (continued)
Figure 6.4 Environmental Impacts (BEES Methodology) of Buffalo Production Operations (per lb Produced)
As shown in Figure 6.4, the manufacturing impacts are primarily driven by the electricity consumed by the Buffalo facility during the manufacturing process, water use and material transport. Electricity is the driver of the human health noncancer, human health criteria air pollutants, and ecotoxicity. Water use is the main driver of human health cancer, eutrophication, habitat alteration and water intake. The ancillary material transportation to and from the facility drives the potential impact categories: acidification, smog, natural resource depletion and ozone depletion.
Table 6.2 Environmental Impacts (BEES Methodology) of Buffalo Production Operations (per lb Produced)
Impact Category
Unit (per lb)
Electricity
Propane
Water
Waste and Scrap
Material Transport
Total
Global warming
g CO2 eq
2.7E+00
4.3E-02
6.0E-01
3.1E+00
3.4E+00
9.9E+00
H+ mmole eq
5.2E-01
1.4E-02
4.8E-01
7.1E-02
7.8E-01
1.9E+00
HH cancer
g C6H6 eq
1.5E-02
1.1E-04
1.9E-02
1.7E-03
2.6E-03
3.8E-02
HH noncancer
g C7H7 eq
2.4E+01
1.3E-01
1.6E+01
3.0E+00
2.7E+00
4.6E+01
microDALYs
1.2E-03
4.4E-06
1.4E-04
3.1E-05
2.2E-04
1.6E-03
g N eq
4.0E-03
4.4E-05
7.6E-03
8.6E-03
2.0E-03
2.2E-02
g 2,4-D eq
3.7E-02
1.7E-04
9.8E-03
2.1E-03
4.3E-03
5.3E-02
g NOX eq
9.2E-03
1.6E-04
9.6E-03
7.3E-04
2.0E-02
3.9E-02
Natural resource depletion
MJ surplus
1.8E-03
3.8E-04
2.4E-03
1.3E-04
4.6E-03
9.3E-03
Habitat alteration
T&E count
3.5E-16
2.8E-19
8.6E-16
5.7E-18
1.0E-16
1.3E-15
liters
1.6E+04
2.7E-02
3.3E+04
1.8E-01
6.2E-01
4.9E+04
g CFC-11 eq
7.9E-08
9.6E-09
3.1E-07
5.3E-09
3.0E-07
7.0E-07
Acidification
HH criteria air pollutants Eutrophication Ecotoxicity Smog
Water intake Ozone depletion
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6.2 Raw Material Impacts In addition to the impacts associated with the manufacturing stage of the product life cycle, examining the raw materials is important to understanding the life cycle of the products. This process includes quantifying all the material inputs including scrap rates. Each raw material has an associated environmental impact.
Figure 6.5 Relative Environmental Impacts of One lb Each of Raw Materials
Titanium dioxide and the heat stabilizer are the most impactful materials on a mass basis. However, these materials are only small constituents in the overall product. As shown in the inventory, Section 4.1 comprises the product formulation of the FRD products. These formulations were the basis for sections 6.2.1-6.2.3 which examines the environmental impacts of the three product formulations (per lb). Table 6.3 Environmental Impacts of One lb Each of Raw Materials
5.0E+01
Impact ModifierArkema 3.0E+03
Impact ModifierElkem 1.5E+03
Internal Regrind
PVC Resin
3.4E+02
Polyethylene Wax 6.7E+02
9.2E+02
9.4E+02
PVC / Wood Regrind 1.1E+01
3.0E+02
2.3E+01
8.5E+02
1.8E+03
1.3E+02
6.4E+02
5.3E+02
5.5E+02
2.2E-03
3.0E+00
3.0E-02
9.3E-01
1.2E+01
1.9E+00
9.5E-01
3.1E+00
g C7H7 eq
3.3E+00
4.7E+03
4.5E+01
3.1E+03
2.1E+04
3.3E+03
3.0E+03
microDALYs
1.3E-03
1.8E-01
6.5E-03
2.5E-01
5.8E-01
4.6E-02
g N eq
3.2E-04
7.1E+00
6.2E-03
2.5E+00
5.9E+00
g 2,4-D eq
7.6E-03
4.0E+00
1.1E-01
2.1E+00
g NOX eq
9.0E-03
4.9E+00
1.7E-01
Natural resource depletion
MJ surplus
3.2E-03
6.7E-01
Habitat alteration
T&E count
0.0E+00
liters g CFC-11 eq
Impact Category
Unit
Calcium Carbonate
Calcium Stearate
External Regrind
Global warming
g CO2 eq
2.6E+00
9.8E+02
H+ mmole eq
9.2E-01
HH cancer
g C6H6 eq
HH noncancer
Acidification
HH criteria air pollutants Eutrophication Ecotoxicity Smog
Water intake Ozone depletion
Stabilizer
Titanium Dioxide
Paraffin Wax
1.7E+03
3.4E+03
3.9E+02
4.5E+00
1.5E+03
1.1E+03
1.3E+02
3.0E+00
6.2E-03
7.6E+00
1.4E+01
1.2E+00
6.6E+03
5.9E+03
1.2E+01
5.3E+04
3.5E+04
1.8E+03
1.8E-01
1.7E-01
1.6E-01
1.1E-03
1.6E+00
5.3E-01
4.1E-02
6.8E-01
3.4E-01
2.1E+00
1.5E+00
2.3E-03
6.4E+00
2.5E+01
4.6E-01
1.8E+01
1.5E+00
3.6E+00
5.3E+00
4.8E+00
2.2E-02
8.3E+00
4.3E+01
1.4E+00
7.0E+00
5.6E+00
1.5E+00
1.6E+00
2.3E+00
2.1E+00
5.4E-02
1.2E+01
1.2E+01
1.6E+00
1.8E-02
7.3E+00
1.5E+00
3.2E+00
5.2E+00
2.9E+00
3.4E+00
8.9E-03
2.3E+00
3.1E+00
3.5E+00
2.3E-14
0.0E+00
3.0E-15
3.6E-14
3.9E-15
9.6E-15
1.7E-14
1.6E-14
2.8E-18
5.3E-14
1.1E-13
1.5E-14
0.0E+00
1.0E+03
0.0E+00
1.4E+02
5.7E+03
2.4E+02
4.6E+02
1.7E+03
1.6E+03
4.8E-01
3.8E+03
9.2E+03
3.0E+02
8.5E-10
2.3E-05
5.0E-10
5.3E-06
4.5E-04
2.9E-06
5.2E-06
5.0E-04
6.0E-04
1.9E-09
4.4E-04
5.1E-04
1.3E-05
Paraffin
24
CertainTeed Fence, Rail and Deck
Life Cycle Assessment
6.2 Raw Material Impacts (continued) 6.2.1 Bufftech Vinyl Fence Raw Materials To investigate these raw material impacts further, Table 6.4 illustrates the environmental impact of each of the major raw materials used in the production of the vinyl fence products, in the proportions found in the average Bufftech product. In order to illustrate these impacts, the BEES impact methodology was used to assess the impacts of the raw materials in the proportions according to the recipe detailed in Table 4.1.
Table 6.4 Environmental Impact (BEES Methodology) Distribution of Vinyl Rail / Fence Formulation
Impact Category
Unit
PVC Resin
Titanium Dioxide
Global warming
g CO2 eq
5.1E+02
5.5E+01
Polyethylene Wax 1.3E+00
Calcium Stearate
Paraffin
Stabilizer
7.9E+00
3.7E+00
1.2E+01
Impact ModifierArkema 3.6E+01
H+ mmole eq
3.0E+02
1.8E+01
1.3E+00
2.4E+00
1.5E+00
1.0E+01
HH cancer
g C6H6 eq
1.6E+00
2.3E-01
1.9E-03
2.4E-02
2.1E-02
HH noncancer
g C7H7 eq
3.2E+03
5.6E+02
6.1E+00
3.8E+01
microDALYs
8.7E-02
8.5E-03
3.6E-04
g N eq
8.2E-01
4.0E-01
g 2,4-D eq
2.6E+00
g NOX eq
Natural resource depletion Habitat alteration
Acidification
HH criteria air pollutants Eutrophication Ecotoxicity Smog
Water intake Ozone depletion
1.9E-01
Impact ModifierArkema 8.3E+00
1.0E+01
6.8E-02
1.0E+01
7.2E+00
3.0E+02
5.3E-02
1.1E-02
1.7E-04
6.9E-02
9.6E-03
1.6E+00
3.6E+01
3.7E+02
3.7E+01
2.5E-01
1.2E+02
1.5E+01
3.2E+03
1.4E-03
5.1E-04
1.1E-02
3.0E-03
9.7E-05
3.2E-03
2.1E-03
8.7E-02
6.8E-04
5.7E-02
7.5E-03
4.5E-02
3.0E-02
2.4E-05
3.3E-02
2.0E-03
8.2E-01
6.8E-01
7.2E-03
3.2E-02
1.6E-02
5.8E-02
2.5E-02
5.6E-04
1.0E-01
3.5E-02
2.6E+00
1.1E+00
1.9E-01
3.2E-03
3.9E-02
1.6E-02
8.2E-02
8.4E-02
6.6E-04
3.1E-02
5.4E-02
1.1E+00
MJ surplus
1.8E+00
5.0E-02
1.0E-02
5.3E-03
3.5E-02
1.6E-02
8.7E-02
2.4E-04
8.4E-03
5.6E-03
1.8E+00
T&E count
8.7E-15
1.8E-15
1.9E-17
1.8E-16
4.3E-17
3.7E-16
3.7E-17
–
2.0E-16
–
8.7E-15
liters
9.0E+02
1.5E+02
9.2E-01
8.3E+00
2.7E+00
2.7E+01
1.7E+00
–
3.2E+01
–
9.0E+02
g CFC-11 eq
3.3E-04
8.1E-06
1.0E-08
1.8E-07
3.1E-08
3.1E-06
6.4E-08
6.3E-11
2.5E-06
1.6E-10
3.3E-04
Calcium Carbonate
External Regrind
Total
1.6E+01
5.1E+02
25
CertainTeed Fence, Rail and Deck
Life Cycle Assessment
6.2 Raw Material Impacts (continued) 6.2.1 Bufftech Vinyl Fence Raw Materials (continued)
Figure 6.6 Relative Environmental Impact (BEES Methodology) Distribution of Vinyl Rail / Fence Formulation
The PVC resin is the driver of environmental impacts in the raw materials stage of vinyl fence products. Titanium dioxide does have some impact on the raw materials stage of the fence as well. While external regrind is 32% of the formulation, this material has only a little impact on the overall raw materials stage. As regrind is recycled content, only the processing from the regrind supplier was considered; the upstream burdens and impacts from the PVC was excluded according to the cutoff methodology as the assumption is made that the first product will claim the burden of the production of PVC, and not the fence product.
26
CertainTeed Fence, Rail and Deck
Life Cycle Assessment
6.2 Raw Material Impacts (continued) 6.2.2 Kingston Vinyl Rail Raw Materials
Figure 6.7 Relative Environmental Impact (BEES Methodology) Distribution of Kingston Rail Formulation
The PVC resin is the driver of environmental impacts in the raw materials stage of vinyl fence products. Titanium dioxide does have some impact on the raw materials stage of the fence as well.
27
CertainTeed Fence, Rail and Deck
Life Cycle Assessment
6.2 Raw Material Impacts (continued) 6.2.2 Kingston Vinyl Rail Raw Materials (continued)
Table 6.5 Environmental Impact (BEES Methodology) Distribution of Kingston Vinyl Rail Formulation (per lb)
Impact Category
Unit (per lb)
PVC Resin
Titanium Dioxide
Global warming
g CO2 eq
5.1E+02
5.5E+01
Polyethylene Wax 1.3E+00
Calcium Stearate
Paraffin
Stabilizer
7.9E+00
3.7E+00
1.1E+01
Impact ModifierArkema 3.6E+01
H+ mmole eq
3.0E+02
1.8E+01
1.3E+00
2.4E+00
1.5E+00
1.0E+01
HH cancer
g C6H6 eq
1.6E+00
2.3E-01
1.5E-03
2.4E-02
2.1E-02
HH noncancer
g C7H7 eq
3.2E+03
5.6E+02
4.9E+00
3.8E+01
microDALYs
8.7E-02
8.5E-03
2.9E-04
g N eq
8.2E-01
4.0E-01
g 2,4-D eq
2.6E+00
g NOX eq
Natural resource depletion Habitat alteration
Acidification
HH criteria air pollutants Eutrophication Ecotoxicity Smog
Water intake Ozone depletion
1.9E-01
Impact ModifierArkema 8.3E+00
1.0E+01
6.8E-02
1.0E+01
7.2E+00
3.6E+02
5.1E-02
1.1E-02
1.7E-04
6.9E-02
9.6E-03
2.0E+00
3.6E+01
3.6E+02
3.7E+01
2.5E-01
1.2E+02
1.5E+01
4.4E+03
1.4E-03
5.1E-04
1.1E-02
3.0E-03
9.7E-05
3.2E-03
2.1E-03
1.2E-01
5.4E-04
5.7E-02
7.5E-03
4.4E-02
3.0E-02
2.4E-05
3.3E-02
2.0E-03
1.4E-00
6.8E-01
5.7E-03
3.2E-02
1.6E-02
5.6E-02
2.5E-02
5.6E-04
1.0E-01
3.5E-02
3.6E+00
1.1E+00
1.9E-01
2.6E-03
3.9E-02
1.6E-02
7.9E-02
8.4E-02
6.6E-04
3.1E-02
5.4E-02
1.6E+00
MJ surplus
1.8E+00
5.0E-02
8.4E-03
5.3E-03
3.5E-02
1.6E-02
8.7E-02
2.4E-04
8.4E-03
5.6E-03
2.0E+00
T&E count
8.7E-15
1.8E-15
1.5E-17
1.8E-16
4.3E-17
3.6E-16
3.7E-17
—
2.0E-16
—
1.1E-14
liters
9.0E+02
1.5E+02
7.3E-01
8.3E+00
2.7E+00
2.6E+01
1.7E+00
—
3.2E+01
—
1.1E+03
g CFC-11 eq
3.3E-04
8.1E-06
8.3E-09
1.8E-07
3.1E-08
3.0E-06
6.4E-08
6.3E-11
2.5E-06
1.6E-10
3.4E-04
Calcium Carbonate
External Regrind
Total
1.6E+01
6.5E+02
28
CertainTeed Fence, Rail and Deck
Life Cycle Assessment
6.2 Raw Material Impacts (continued) 6.2.3 Panorama Composite Rail Raw Materials
Figure 6.8 Relative Environmental Impact (BEES Methodology) Distribution of Panorama Rail Formulation
Table 6.6 and Figure 6.8 illustrate the relative environmental impact of each of the major raw materials used in the production of Panorama, in the proportions found in the average Panorama product. The PVC resin contributes the majority of the raw material impacts.
29
CertainTeed Fence, Rail and Deck
Life Cycle Assessment
6.2 Raw Material Impacts (continued) 6.2.3 Panorama Composite Rail Raw Materials (continued)
Table 6.6 Environmental Impact (BEES Methodology) Distribution of Panorama Rail Formulation (per lb)
Impact Category
Unit (per lb)
PVC / Wood Regrind
PVC Resin
Titanium Dioxide
Polyethylene Wax
Calcium Stearate
Paraffin
Stabilizer
Impact Modifier-Arkema
Calcium Carbonate
Total
Global warming
g CO2 eq
9.9E+00
7.7E+01
2.7E+01
1.1E-01
9.8E-01
3.7E-01
1.7E+00
7.2E+00
1.1E-02
1.2E+02
H+ mmole eq
4.1E+00
4.5E+01
9.1E+00
1.0E-01
3.0E-01
1.5E-01
1.5E+00
2.0E+00
3.9E-03
6.3E+01
HH cancer
g C6H6 eq
5.6E-03
2.4E-01
1.1E-01
1.5E-04
3.0E-03
2.1E-03
7.6E-03
2.2E-03
9.6E-06
3.8E-01
HH noncancer
g C7H7 eq
1.1E+01
4.9E+02
2.8E+02
4.9E-01
4.7E+00
3.6E+00
5.3E+01
7.4E+00
1.4E-02
8.5E+02
microDALYs
1.0E-03
1.3E-02
4.3E-03
2.9E-05
1.8E-04
5.1E-05
1.6E-03
6.0E-04
5.6E-06
2.1E-02
g N eq
2.1E-03
1.2E-01
2.0E-01
5.4E-05
7.1E-03
7.5E-04
6.4E-03
6.1E-03
1.4E-06
3.5E-01
g 2,4-D eq
2.0E-02
3.9E-01
3.4E-01
5.7E-04
4.0E-03
1.6E-03
8.3E-03
5.1E-03
3.2E-05
7.7E-01
g NOX eq
4.8E-02
1.7E-01
9.3E-02
2.6E-04
4.9E-03
1.6E-03
1.2E-02
1.7E-02
3.9E-05
3.5E-01
Natural resource depletion
MJ surplus
8.0E-03
2.7E-01
2.5E-02
8.4E-04
6.7E-04
3.5E-03
2.3E-03
1.7E-02
1.4E-05
3.3E-01
Habitat alteration
T&E count
2.5E-18
1.3E-15
8.8E-16
1.5E-18
2.3E-17
4.3E-18
5.3E-17
7.3E-18
—
2.3E-15
liters
4.3E-01
1.4E+02
7.4E+01
7.3E-02
1.0E+00
2.7E-01
3.8E+00
3.5E-01
—
2.1E+02
g CFC-11 eq
1.7E-09
4.9E-05
4.0E-06
8.3E-10
2.3E-08
3.1E-09
4.4E-07
1.3E-08
3.7E-12
5.4E-05
Acidification
HH criteria air pollutants Eutrophication Ecotoxicity Smog
Water intake Ozone depletion
30
CertainTeed Fence, Rail and Deck
Life Cycle Assessment
6.3 Installation and Use Phase An average of 25 years is suggested as the likely life of most vinyl rail and composite rail products. Lifetime warranties are provided by CertainTeed for fence products, so a lifetime of 50 years can be assumed for vinyl fence. During the use phase, the products may be cleaned with soapy water, however, due to the high variability of cleaning this phase was excluded from the scope. No additional impacts are contributed by the use phase.
Figure 6.9 Bufftech Chesterfield Installation Materials (per 8ft section)
6.3.1 Bufftech Vinyl Fence Installation Materials Hardware, footings, post caps and inserts are included in this life cycle assessment as all of these materials are required for the Bufftech fencing systems. Table 6.7 and Figure 6.9 show the results of the impact assessment of the installation materials recommended for the Chesterfield fencing product. Table 6.7 Bufftech Chesterfield Installation Materials (per 8ft section)
Impact Category
Unit
PVC Posts and Post Caps
Stainless Steel Hardware
Concrete Footing
Steel Inserts
Total
Global warming
g CO2 eq
1.6E+04
1.1E+03
9.9E+03
2.6E+04
5.4E+04
H+ mmole eq
9.7E+03
3.4E+02
2.7E+03
8.2E+03
2.1E+04
HH cancer
g C6H6 eq
5.2E+01
4.2E+01
4.1E+01
1.0E+03
1.2E+03
HH noncancer
g C7H7 eq
1.0E+05
2.5E+04
6.9E+04
6.1E+05
8.0E+05
microDALYs
2.8E+00
4.5E-01
1.1E+00
1.1E+01
1.5E+01
g N eq
2.6E+01
3.6E+00
1.2E+01
8.8E+01
1.3E+02
g 2,4-D eq
8.4E+01
1.4E+01
6.1E+01
3.5E+02
5.1E+02
g NOX eq
3.7E+01
3.5E+00
4.5E+01
8.5E+01
1.7E+02
Natural resource depletion
MJ surplus
5.9E+01
9.0E-01
8.3E+00
2.2E+01
9.0E+01
Habitat alteration
T&E count
2.8E-13
8.3E-14
1.2E-13
2.0E-12
2.5E-12
liters
2.9E+04
2.5E+04
1.3E+04
6.0E+05
6.7E+05
g CFC-11 eq
1.0E-02
1.5E-05
2.0E-04
3.6E-04
1.1E-02
Acidification
HH criteria air pollutants Eutrophication Ecotoxicity Smog
Water intake Ozone depletion
31
CertainTeed Fence, Rail and Deck
Life Cycle Assessment
6.3 Installation and Use Phase (continued) 6.3.1 Bufftech Vinyl Fence Installation Materials (continued)
Figure 6.10 Bufftech New Lexington Installation Materials (per 8ft section)
For Chesterfield, the steel inserts are the main driver of the installation materials in most categories. Posts and caps (made from PVC) are a second driver of installing PVC fence, and are the primary driver in categories of global warming, acidification, natural resource depletion and ozone depletion. Table 6.8 and Figure 6.10 show the results of the impact assessment of the installation materials recommended for New Lexington. The results for New Lexington are very similar, since the amount of installation materials required are similar to that of Chesterfield. For both fence types, Chesterfield and New Lexington, steel inserts and PVC posts and caps Table 6.8 Bufftech New Lexington Installation Materials (per 8ft section)
Impact Category
Unit
PVC Posts and Post Caps
Stainless Steel Hardware
Concrete Footing
Steel Inserts
Total
Global warming
g CO2 eq
1.4E+04
1.1E+03
9.9E+03
2.8E+04
5.3E+04
H+ mmole eq
8.1E+03
3.4E+02
2.7E+03
8.9E+03
2.0E+04
HH cancer
g C6H6 eq
4.3E+01
4.2E+01
4.1E+01
1.1E+03
1.2E+03
HH noncancer
g C7H7 eq
8.6E+04
2.5E+04
6.9E+04
6.6E+05
8.4E+05
microDALYs
2.3E+00
4.5E-01
1.1E+00
1.2E+01
1.6E+01
g N eq
2.2E+01
3.6E+00
1.2E+01
9.5E+01
1.3E+02
g 2,4-D eq
6.9E+01
1.4E+01
6.1E+01
3.8E+02
5.2E+02
g NOX eq
3.0E+01
3.5E+00
4.5E+01
9.2E+01
1.7E+02
Natural resource depletion
MJ surplus
4.9E+01
9.0E-01
8.3E+00
2.4E+01
8.1E+01
Habitat alteration
T&E count
2.3E-13
8.3E-14
1.2E-13
2.2E-12
2.6E-12
liters
2.4E+04
2.5E+04
1.3E+04
6.5E+05
7.1E+05
g CFC-11 eq
8.7E-03
1.5E-05
2.0E-04
3.8E-04
9.3E-03
Acidification
HH criteria air pollutants Eutrophication Ecotoxicity Smog
Water intake Ozone depletion
32
CertainTeed Fence, Rail and Deck
Life Cycle Assessment
6.3 Installation and Use Phase (continued) 6.3.1 Bufftech Vinyl Fence Installation Materials (continued)
Figure 6.11 Kingston Installation Materials (per 8ft section)
are a large driver of installation materials. By incorporating recycled content into steel, or investigating other materials such as aluminum may help reduce the installation phase of the fence life cycle. 6.3.2 Kingston Vinyl Rail Installation Materials Kingston rail requires aluminum inserts, post covers and caps and additional hardware for installation and use. These materials were included in the railing system in the installation stage of the product life cycle. Table 6.9 shows the potential environmental impact results of these materials for an eight foot section of railing. Hardware is the dominant driver of the installation materials for the Kingston railing system for the human health impact Table 6.9 Kingston Installation Materials (per 8ft section) categories (cancer, noncancer and criteria air pollutants) as well as Impact Category Unit PVC Posts and Post Caps Stainless Steel Hardware eutrophication, ecotoxicity, habitat Global warming g CO2 eq 4.5E+03 2.1E+03 alteration and water intake. Posts Acidification H+ mmole eq 2.6E+03 6.7E+02 and post caps drive global warming, HH cancer g C6H6 eq 1.4E+01 8.4E+01 acidification, natural resource depletion, and ozone depletion due to the upstream production of PVC resin used in the caps.
Aluminum Inserts
Total
3.0E+03
9.6E+03
1.3E+03
4.6E+03
1.4E+00
9.9E+01
g C7H7 eq
2.8E+04
4.9E+04
2.6E+03
8.0E+04
microDALYs
7.6E-01
8.9E-01
4.7E+01
2.1E+00
g N eq
7.2E+00
7.1E+00
3.4E-01
1.5E+01
g 2,4-D eq
2.3E+01
2.8E+01
6.8E+00
5.8E+01
g NOX eq
9.9E+00
6.9E+00
8.6E+00
2.5E+01
Natural resource depletion
MJ surplus
1.6E+01
1.8E+00
3.7E+00
2.1E+01
Habitat alteration
T&E count
7.6E-14
1.6E-13
–
2.4E-13
liters
7.8E+03
4.9E+04
–
5.7E+04
g CFC-11 eq
2.8E-03
2.9E-05
4.2E-06
2.9E-03
HH noncancer HH criteria air pollutants Eutrophication Ecotoxicity Smog
Water intake Ozone depletion
33
CertainTeed Fence, Rail and Deck
Life Cycle Assessment
6.3 Installation and Use Phase (continued) 6.3.3 Panorama Composite Rail Installation Materials
Figure 6.12 Panorama Rail Installation Materials (per 8ft section)
Panorama requires post covers and caps and additional hardware for installation and use. These materials were included in the railing system in the installation stage of the product life cycle. Hardware is the dominant driver of the installation materials for the composite railing system. Posts and post caps drive ozone depletion, due to the upstream production of PVC resin used in the caps.
Table 6.10 Panorama Rail Installation Materials (per 8ft section)
Impact Category
Unit
Posts and Post Caps
Stainless Steel Hardware
Total
Global warming
g CO2 eq
1.9E+03
8.3E+03
1.0E+04
H+ mmole eq
1.0E+03
2.6E+03
3.6E+03
HH cancer
g C6H6 eq
5.8E+00
3.2E+02
3.3E+02
HH noncancer
g C7H7 eq
1.3E+04
1.9E+05
2.0E+05
microDALYs
3.2E-01
3.5E+00
3.8E+00
g N eq
4.6E+00
2.8E+01
3.2E+01
g 2,4-D eq
1.1E+01
1.1E+02
1.2E+02
g NOX eq
4.9E+00
2.7E+01
3.2E+01
Natural resource depletion
MJ surplus
5.6E+00
6.9E-00
1.2E+01
Habitat alteration
T&E count
3.4E-14
6.4E-13
6.7E-13
liters
3.3E+03
1.9E+05
1.9E+05
g CFC-11 eq
9.3E-04
1.1E-04
1.0E-03
Acidification
HH criteria air pollutants Eutrophication Ecotoxicity Smog
Water intake Ozone depletion
34
CertainTeed Fence, Rail and Deck
Life Cycle Assessment
6.4 Overall Environmental Impact 6.4.1 Overall Energy and Carbon Life Cycle Impacts Energy is consumed in raw materials extraction and processing, manufacturing, transportation, use phase, and final product disposal. The cumulative energy demand (CED) represents all the energy needed to convert a material to its final product. The values for cumulative energy demand for an eight foot section of Bufftech fence, Kingston rail and Panorama rail are listed in Table 6.5 and illustrated in Figure 6.13 and Figure 6.14.
Table 6.11 Cumulative Energy Demand (CED) for Vinyl Fence, Vinyl Rail and Composite Rail (MJ / 8ft)
Bufftech® Chesterfield Fence
Bufftech® New Lexington Fence
Kingston Railing System
Panorama® Railing System
(MJ / 8ft)
(MJ / 8ft)
(MJ / 8ft)
(MJ / 8ft)
Raw materials
1,185
888
510
125
Raw materials transportation
25
19
11
15
Manufacturing
128
96
52
79
Product shipping
37
28
97
147
Packaging
47
35
31
65
Installation
967
920
198
176
Waste disposal
59
44
39
37
2,448
2,030
938
644
Total
35
CertainTeed Fence, Rail and Deck
Life Cycle Assessment
6.4 Overall Environmental Impact (continued) 6.4.1 Overall Energy and Carbon Life Cycle Impacts (continued)
Figure 6.13 Cumulative Energy Demand (CED) for the Life Cycle Stages of CertainTeed Bufftech Fence Systems (MJ / 8ft)
Raw materials drive the life cycle impacts for the cumulative energy demand of Bufftech fence and Kingston railing. Installation materials are a close second driver of Bufftech fence due to the steel inserts and concrete. As Panorama uses recycled content in the formulation which reduces impacts in that stage, installation materials are the primary drivers of the composite railing life cycle energy demand. Packaging has significant impacts on the overall life cycle for the railing products. The main driver of packaging is the lumber used for packaging – some lumber assumed for railing products is cut to size and drives the impacts. Global warming potential (GWP) was also analyzed for the same life cycle stages. Similarly, the GWP results represent all the greenhouse gas emissions created in the extraction and conversion of the various raw materials through final disposal of the product. The values for GWP for an eight foot section of the fence and rail products are listed in Table 6.12 and illustrated in Figures 6.15 and 6.16.
Figure 6.14 Cumulative Energy Demand (CED) for the Life Cycle Stages of Kingston and Panorama Railing Systems (MJ / 8ft)
36
CertainTeed Fence, Rail and Deck
Life Cycle Assessment
6.4 Overall Environmental Impact (continued) Figure 6.15 Global Warming Potential (GWP) for the Life Cycle Stages of BuffTech Fence (g CO2 eq / 8ft product)
Table 6.12 Global Warming Potential (GWP) Values for Vinyl Fence, Vinyl Rail and Composite Rail (g CO2 eq / 8ft)
Bufftech® Chesterfield Fence
Bufftech® New Lexington Fence
Kingston Railing System
Panorama® Railing System
(g CO2 / 8ft)
(g CO2 / 8ft)
(g CO2 / 8ft)
(g CO2 / 8ft)
Raw materials
45,933
34,425
19,755
5,487
Raw materials transportation
1,881
1,410
813
1,074
Manufacturing
701
525
285
232
Product shipping
1,435
1,075
3,344
4,953
Packaging
3,412
2,557
2,257
4,752
Installation
53,764
53,038
9,630
10,224
Waste disposal
3,815
2,860
3,520
2,385
110,941
95,892
39,604
29,107
Total
37
CertainTeed Fence, Rail and Deck
Life Cycle Assessment
6.4 Overall Environmental Impact (continued) 6.4.1 Overall Energy and Carbon Life Cycle Impacts (continued) Installation materials are the primary driver stage of the carbon footprint of Bufftech fence and Panorama composite rail while the raw materials are the driver stage of the Kingston rail. Panorama has a reduced carbon footprint in the raw materials stage from the integration of recycled content which is why the raw materials do not drive the overall life cycle for that product. Raw materials extraction and processing are the second largest life cycle stage for Bufftech fence.
Figure 6.16 Global Warming Potential (GWP) for the Life Cycle Stages of CertainTeed Railing Systems (g CO2 eq / 8ft)
38
CertainTeed Fence, Rail and Deck
Life Cycle Assessment
6.4 Overall Environmental Impact (continued) 6.4.2 Bufftech Overall Environmental Impacts The graphs in this section are designed to communicate the overall environmental impacts of the fence and rail products using the BEES methodology. For more detail on the impact categories and the BEES methodology, see Section 5.2 above. Table 6.13 and Figure 6.17 demonstrate the overall environmental impact (using the BEES methodology) of manufacturing an eight foot section of Bufftech Chesterfield vinyl fence. The figure illustrates the relative impact contribution from each of the seven life cycle stages (Raw Material Extraction and Processing, Raw Material Shipping, Manufacturing, Product Shipping, Packaging, Installation, and Final Disposal) to each of the environmental impacts. In this analysis, raw material transportation impacts are separated from the “Raw Material Extraction and Processing” stage to show the impacts of that transportation has on procurement.
Table 6.13 Bufftech Chesterfield Vinyl Fence Environmental Impacts per 8ft
Impact Category
Unit (per 8ft)
Raw Materials
Raw Material Transport
Processing
Packaging
Final Product Transport
Installation
End of Life
Total
Global warming
g CO2 eq
4.6E+04
1.9E+03
2.0E+03
1.4E+03
3.4E+03
5.4E+04
3.8E+03
1.1E+05
H+ mmole eq
2.6E+04
1.2E+03
2.1E+02
3.6E+02
1.1E+03
2.1E+04
1.2E+03
5.1E+04
HH cancer
g C6H6 eq
1.4E+02
9.1E-01
4.9E+01
2.7E+00
1.5E+00
1.2E+03
9.6E+01
1.4E+03
HH noncancer
g C7H7 eq
3.1E+05
2.8E+03
2.1E+05
4.2E+03
1.2E+03
8.0E+05
1.4E+05
1.3E+06
microDALYs
8.3E+00
1.6E-01
1.3E-01
1.9E-01
1.6E-01
1.5E+01
3.7E-01
2.5E+01
g N eq
9.9E+01
1.4E+00
6.4E+00
2.1E+00
1.1E+00
1.3E+02
3.6E+00
2.4E+02
g 2,4-D eq
2.5E+02
3.5E+00
9.8E+01
3.2E+00
4.4E+00
5.1E+02
3.1E+01
8.2E+02
g NOX eq
1.1E+02
3.3E+01
4.6E+00
6.3E+00
2.8E+01
1.7E+02
3.1E+01
3.9E+02
Natural resource depletion
MJ surplus
1.4E+02
3.4E+00
7.5E-01
4.4E+00
6.1E+00
9.0E+01
7.6E+00
2.6E+02
Habitat alteration
T&E count
8.0E-13
1.5E-15
3.9E-14
1.3E-14
0.0E+00
2.5E-12
1.1E-12
4.4E-12
liters
7.9E+04
2.6E+02
1.1E+06
1.3E+03
0.0E+00
6.7E+05
1.3E+03
1.9E+06
g CFC-11 eq
2.4E-02
9.8E-07
7.1E-05
2.7E-05
1.3E-07
1.1E+02
4.4E-04
3.6E-02
Acidification
HH criteria air pollutants Eutrophication Ecotoxicity Smog
Water intake Ozone depletion
39
CertainTeed Fence, Rail and Deck
Life Cycle Assessment
6.4 Overall Environmental Impact (continued) 6.4.2 Bufftech Overall Environmental Impacts (continued) Figure 6.17 shows that for vinyl fence, installation contributes a majority of the impact in most categories except for water intake. A significant portion of the installation impact is related to the steel inserts, as detailed in Section 6.3.1. For water intake, the majority occurs in the manufacturing stage. This intake is caused by the electricity generation from hydropower which consumes some water in the process of generating energy. Table 6.14 and Figure 6.18 demonstrate the overall environmental impact (using the BEES methodology) of manufacturing one kilogram of the vinyl rail product. This figure illustrates the relative impact contribution from each of the seven life cycle stages (raw material extraction and processing, raw material shipping, manufacturing, packaging, product shipping, installation and final disposal) to each of the environmental impacts. In this analysis, raw material transportation impacts are separated from the “raw material extraction and processing” stage.
Figure 6.17 Environmental Impacts of Bufftech Chesterfield Vinyl Fence (BEES Impact Assessment Methodology)
40
CertainTeed Fence, Rail and Deck
Life Cycle Assessment
6.4 Overall Environmental Impact (continued) 6.4.2 Bufftech Overall Environmental Impacts (continued)
Table 6.14 Bufftech New Lexington Vinyl Fence Environmental Impacts per 8ft
Impact Category
Unit (per 8ft)
Raw Materials
Raw Material Transport
Processing
Packaging
Final Product Transport
Installation
End of Life
Total
Global warming
g CO2 eq
3.4E+04
1.4E+03
1.5E+03
1.1E+03
2.6E+03
5.3E+04
2.9E+03
1.1E+05
H+ mmole eq
1.9E+04
9.1E+02
1.5E+02
2.7E+02
8.5E+02
2.0E+04
9.3E+02
5.0E+04
HH cancer
g C6H6 eq
1.1E+02
6.8E-01
3.7E+01
2.0E+00
1.1E+00
1.2E+03
7.2E+01
1.5E+03
HH noncancer
g C7H7 eq
2.3E+05
2.1E+03
1.6E+05
3.1E+03
8.9E+02
8.4E+05
1.1E+05
1.3E+06
microDALYs
6.2E+00
1.2E-01
9.7E-02
1.5E-01
1.2E-01
1.6E+01
2.8E-01
2.5E+01
g N eq
7.4E+01
1.1E+00
4.8E+00
1.5E+00
8.2E-01
1.3E+02
2.7E+00
2.4E+02
g 2,4-D eq
1.9E+02
2.6E+00
7.3E+01
2.4E+00
3.3E+00
5.2E+02
2.4E+01
8.2E+02
g NOX eq
8.6E+01
2.5E+01
3.5E+00
4.8E+00
2.1E+01
1.7E+02
2.3E+01
3.6E+02
Natural resource depletion
MJ surplus
1.1E+02
2.5E+00
5.7E-01
3.3E+00
4.6E+00
8.1E+01
5.7E+00
2.5E+02
Habitat alteration
T&E count
6.0E-13
1.1E-15
2.9E-14
9.9E-15
0.0E+00
2.6E-12
8.4E-13
4.3E-12
liters
5.9E+04
1.9E+02
8.6E+05
9.6E+02
0.0E+00
7.1E+05
9.7E+02
1.7E+06
g CFC-11 eq
1.8E-02
7.3E-07
5.3E-05
2.0E-05
9.9E-08
9.3E-03
3.3E-04
3.6E-02
Acidification
HH criteria air pollutants Eutrophication Ecotoxicity Smog
Water intake Ozone depletion
41
CertainTeed Fence, Rail and Deck
Life Cycle Assessment
6.4 Overall Environmental Impact (continued) 6.4.2 Bufftech Overall Environmental Impacts (continued)
Figure 6.18 Environmental impacts of Bufftech New Lexington Vinyl Fence (BEES Impact Assessment Methodology)
42
CertainTeed Fence, Rail and Deck
Life Cycle Assessment
6.4 Overall Environmental Impact (continued) 6.4.2 Bufftech Overall Environmental Impacts (continued) A comparison of the two product lines of BuffTech is shown below in Figure 6.19. Chesterfield is generally higher in impacts compared to New Lexington. For the water intake and human health cancer categories, both product types are equivalent in impacts.
Figure 6.19 Overall Life Cycle Comparison of the New Lexington and Chesterfield Fence Lines
43
CertainTeed Fence, Rail and Deck
Life Cycle Assessment
6.4 Overall Environmental Impact (continued) 6.4.3 Kingston Overall Environmental Impacts Table 6.15 demonstrate the overall environmental impact (using the BEES methodology) of manufacturing eight feet of the Kingston vinyl railing system. This figure illustrates the relative impact contribution from each of the seven life cycle stages to each of the environmental impacts.
Table 6.15 Environmental Impacts of Kingston Vinyl Railing System (per 8ft)
Impact Category
Unit (per 8ft)
Raw Materials
Raw Material Transport
Processing
Packaging
Final Product Transport
Installation
End of Life
Total
Global warming
g CO2 eq
2.0E+04
8.1E+02
2.8E+02
3.3E+03
2.3E+03
9.6E+03
3.5E+03
4.0E+04
H+ mmole eq
1.1E+04
5.2E+02
5.7E+01
9.6E+02
7.5E+02
4.6E+03
9.7E+02
1.9E+04
HH cancer
g C6H6 eq
6.2E+01
3.9E-01
3.7E+00
9.0E+00
1.1E+00
9.9E+01
3.6E+01
2.1E+02
HH noncancer
g C7H7 eq
1.3E+05
1.2E+03
1.3E+04
1.7E+04
3.4E+03
8.0E+04
4.0E+05
6.5E+05
microDALYs
3.6E+00
6.7E-02
4.7E-02
5.0E-01
1.1E-01
2.1E+00
2.4E-01
6.6E+00
g N eq
4.2E+01
6.1E-01
9.2E-01
6.4E+00
9.1E-01
1.5E+01
1.6E+02
2.2E+02
g 2,4-D eq
1.1E+02
1.5E+00
6.9E+00
1.1E+01
3.8E+00
5.8E+01
1.7E+02
3.6E+02
g NOX eq
4.9E+01
1.4E+01
1.2E+00
1.4E+01
1.8E+01
2.5E+01
2.1E+01
1.4E+02
Natural resource depletion
MJ surplus
6.2E+01
1.5E+00
2.7E-01
7.9E+00
4.0E+00
2.1E+01
5.0E+00
1.0E+02
Habitat alteration
T&E count
3.4E-13
6.4E-16
1.4E-14
7.2E-14
1.8E-15
2.4E-13
6.9E-13
1.4E-12
liters
3.4E+04
1.1E+02
4.7E+05
3.9E+03
3.1E+02
5.7E+04
8.6E+02
5.6E+05
g CFC-11 eq
1.0E-02
4.2E-07
2.1E-05
4.4E-05
1.2E-06
2.9E-03
3.0E-04
1.4E-02
Acidification
HH criteria air pollutants Eutrophication Ecotoxicity Smog
Water intake Ozone depletion
44
CertainTeed Fence, Rail and Deck
Life Cycle Assessment
6.4 Overall Environmental Impact (continued) 6.4.3 Kingston Overall Environmental Impacts (continued) Figure 6.20 illustrates the relative impacts of Table 6.15.
Figure 6.20 Environmental Impacts of Kingston Vinyl Railing System
45
CertainTeed Fence, Rail and Deck
Life Cycle Assessment
6.4 Overall Environmental Impact (continued) 6.4.4 Panorama Overall Environmental Impacts Table 6.16 and Figure 6.21 demonstrate the overall environmental impact (using the BEES methodology) of manufacturing eight feet of composite rail product. This figure illustrates the relative impact contribution from each of the seven life cycle stages to each of the environmental impacts.
Table 6.16 Environmental Impacts of Panorama Composite Railing System (per 8ft)
Impact Category
Unit (per 8ft)
Raw Materials
Raw Material Transport
Processing
Packaging
Final Product Transport
Installation
End of Life
Total
Global warming
g CO2 eq
5.5E+03
1.1E+03
2.3E+02
5.0E+03
4.8E+03
1.0E+04
2.4E+03
2.9E+04
H+ mmole eq
2.8E+03
4.1E+02
5.8E+01
1.6E+03
1.6E+03
3.6E+03
7.7E+02
1.1E+04
HH cancer
g C6H6 eq
1.7E+01
5.2E-01
1.7E+00
1.2E+01
2.3E+00
3.3E+02
6.0E+01
4.2E+02
HH noncancer
g C7H7 eq
3.7E+04
1.6E+03
2.4E+03
2.4E+04
7.1E+03
2.0E+05
9.0E+04
3.7E+05
microDALYs
9.2E-01
5.7E-02
6.6E-02
7.1E-01
2.3E-01
3.8E+00
2.3E-01
6.0E+00
g N eq
1.5E+01
4.9E-01
9.5E-01
7.8E+00
1.9E+00
3.2E+01
2.3E+00
6.1E+01
g 2,4-D eq
3.4E+01
1.8E+00
2.5E+00
1.6E+01
7.9E+00
1.2E+02
2.0E+01
2.0E+02
g NOX eq
1.5E+01
1.0E+01
1.2E+00
2.1E+01
3.8E+01
3.2E+01
1.9E+01
1.4E+02
Natural resource depletion
MJ surplus
1.5E+01
1.9E+00
2.8E-01
1.1E+01
8.5E+00
1.2E+01
4.7E+00
5.4E+01
Habitat alteration
T&E count
1.0E-13
8.5E-16
2.0E-14
7.9E-14
3.7E-15
6.7E-13
7.0E-13
1.6E-12
liters
9.5E+03
1.5E+02
2.0E+06
5.9E+03
6.5E+02
1.9E+05
8.1E+02
9.3E+05
g CFC-11 eq
2.4E-03
5.6E-07
2.8E-05
5.4E-05
2.5E-06
1.0E-03
2.8E-04
3.8E-03
Acidification
HH criteria air pollutants Eutrophication Ecotoxicity Smog
Water intake Ozone depletion
46
CertainTeed Fence, Rail and Deck
Life Cycle Assessment
6.4 Overall Environmental Impact (continued) 6.4.4 Panorama Overall Environmental Impacts (continue) Installation is the main driver of impacts for the Panorama railing system in most impact categories except smog, natural resource depletion, water intake, and ozone depletion. Smog is driven by the transportation impacts during distribution. Processing drives water intake due to the hydropower used for energy generation.
Figure 6.21 Environmental Impacts of Panorama Composite Rail (BEES Impact Assessment Methodology)
47
CertainTeed Fence, Rail and Deck
Life Cycle Assessment
7.0 Sensitivity Analyses 7.1 Hydropower Sensitivity Analysis The Buffalo facility has a power purchase agreement with the local hydropower facility which provides all electricity to the plant. Without this agreement, the Buffalo facility would be obtaining their electricity from the local electrical grid, NYPP. A sensitivity analysis was performed to show the difference between the two sources of electricity generation. Table 7.1 and Figure 7.1 show the difference between producing one pound of product using hydropower generated electricity compared to the local electricity grid.
Table 7.1 Sensitivity Analysis on the Electricity Generation Source for the FRD Manufacturing Process (per lb of Product)
Impact Category
Unit (per 8ft)
Hydro
eGrid
Global warming
g CO2 eq
5.3E+00
1.7E+02
H+ mmole eq
1.3E+00
7.5E+01
HH cancer
g C6H6 eq
3.9E+02
1.1E-01
HH noncancer
g C7H7 eq
5.5E+01
1.5E+02
microDALYs
1.5E-03
2.1E-02
g N eq
2.2E-02
3.6E-02
g 2,4-D eq
5.6E-02
3.5E-01
g NOX eq
2.6E-02
4.7E-01
Natural resource depletion
MJ surplus
6.3E-03
1.9E-01
Habitat alteration
T&E count
4.5E-16
1.1E-16
liters
1.6E+04
3.1E+00
g CFC-11 eq
6.3E-07
5.5E-07
Acidification
HH criteria air pollutants Eutrophication Ecotoxicity Smog
Water intake Ozone depletion
Figure 7.1 Sensitivity Analysis on the Electricity Generation Source for the FRD Manufacturing Process
48
CertainTeed Fence, Rail and Deck
Life Cycle Assessment
7.1 Hydropower Sensitivity Analysis (continued) Hydropower has less of a potential environmental impact during the production of fence and railing products than using the local grid except for the categories habitat alteration, water intake and ozone depletion. Acidification is the impact category with the most reductions of 96% while eutrophication is only reduced by 33%. Water intake greatly increases as water is required for the generation of hydropower; however, it is important to note that most of the input water will not be consumed in the turbines but will be returned to the watershed. Since production is only a small part of the life cycle of each of these products, analyses were also conducted for the overall life cycle of both the Kingston and the Panorama Railing systems to show the effect of this purchased power agreement.
Table 7.2 Sensitivity Analysis on the Electricity Generation Source for the Life Cycle of CertainTeed Railing Systems
Impact Category
Unit
Kingston
Panorama
BEES v4.04+
(per 8ft)
Hydro
eGrid
Hydro
eGrid
Global warming
g CO2 eq
4.0E+04
4.4E+04
2.9E+04
3.6E+04
H+ mmole eq
1.9E+04
2.1E+04
1.1E+04
1.4E+04
HH cancer
g C6H6 eq
2.1E+02
2.1E+02
4.2E+02
4.3E+02
HH noncancer
g C7H7 eq
6.5E+05
6.5E+05
3.7E+05
3.7E+05
microDALYs
6.6E+00
7.2E+00
6.0E+00
6.9E+00
g N eq
2.2E+02
2.2E+02
6.1E+01
6.2E+01
g 2,4-D eq
3.6E+02
3.7E+02
2.0E+02
2.2E+02
g NOX eq
1.4E+02
1.6E+02
1.4E+02
1.6E+02
Natural resource depletion
MJ surplus
1.0E+02
1.1E+02
5.4E+01
6.2E+01
Habitat alteration
T&E count
1.4E-12
1.4E-12
1.6E-12
1.6E-12
liters
5.6E+05
9.6E+04
9.3E+05
2.1E+05
g CFC-11 eq
1.4E-02
1.4E-02
3.8E-03
3.8E-03
Acidification
HH criteria air pollutants Eutrophication Ecotoxicity Smog
Water intake Ozone depletion
49
CertainTeed Fence, Rail and Deck
Life Cycle Assessment
7.1 Hydropower Sensitivity Analysis (continued) The potential of ozone depletion, eutrophication, ecotoxicity and human health (cancer and noncancer) from the Kingston product are not significantly influenced by the electricity source for the extrusion of these products. However, global warming, acidification, criteria air pollutants, smog and natural resource depletion decrease between 6% (natural resource depletion) to 12% (global warming and acidification) in the overall life cycle results.
Figure 7.2 Sensitivity Analysis on the Electricity Generation Source for the Life Cycle of the Kingston Railing System
50
CertainTeed Fence, Rail and Deck
Life Cycle Assessment
7.1 Hydropower Sensitivity Analysis (continued) The potential of ozone depletion, habitat alteration, eutrophication and human health (cancer and noncancer) from the railing products are not significantly influenced by the electricity source for the extrusion of these products. However, global warming, acidification, criteria air pollutants, ecotoxicity, smog and natural resource depletion decrease more than 6% (ecotoxicity) to 24% (acidification) in the overall Panorama life cycle results. Water intake significantly increases by 77%; however, this water is not consumed in the generation of electricity, which, providing an analysis on water consumption and not just water intake would be much lower.
Figure 7.3 Sensitivity Analysis on the Electricity Generation Source for the Life Cycle of the Panorama Railing System
51
CertainTeed Fence, Rail and Deck
Life Cycle Assessment
7.2 Recycled Content Sensitivity Analysis CertainTeed integrates external regrind into the vinyl products produced at the Buffalo facility. This recycled content decreases the environmental impacts of the life cycle of the products. To show an example of the reduced impacts, a sensitivity was performed on the formulation of the Bufftech products. The external regrind was removed from the formulation. Table 7.3 shows the environmental impacts of a 100% virgin fence product.
Table 7.3 Overall Life Cycle Environmental Impacts of BuffTech Chesterfield Fence with and without Recycled Content
Bufftech Chesterfield Fence Impact Category
Unit
Current Formulation (32% Recycled Content)
Formulation with No Recycled Content
Global warming
g CO2 eq
1.1E+05
1.3E+05
H+ mmole eq
5.1E+04
6.2E+04
HH cancer
g C6H6 eq
1.4E+03
1.5E+03
HH noncancer
g C7H7 eq
1.3E+06
1.4E+06
microDALYs
2.5E+01
2.8E+01
g N eq
2.4E+02
2.9E+02
g 2,4-D eq
8.2E+02
9.3E+02
g NOX eq
3.9E+02
4.3E+02
Natural resource depletion
MJ surplus
2.6E+02
3.2E+02
Indoor air quality
g TVOC eq
0.0E+00
0.0E+00
Habitat alteration
T&E count
4.4E-12
4.8E-12
liters
1.9E+06
1.9E+06
g CFC-11 eq
3.6E-02
4.7E-02
Acidification
HH criteria air pollutants Eutrophication Ecotoxicity Smog
Water intake Ozone depletion
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CertainTeed Fence, Rail and Deck
Life Cycle Assessment
7.2 Recycled Content Sensitivity Analysis (continued) By incorporating recycled content into the fence and railing formulations, the overall life cycle impacts are reduced between 2% (in water intake) to 24% (in ozone depletion). CertainTeed should continue to integrate recycled content into these products to continue reducing the overall life cycle of the FRD products.
Figure 7.4 Relative Overall Life Cycle Environmental Impacts of Bufftech Chesterfield Fence with and without Recycled Content
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CertainTeed Fence, Rail and Deck
Life Cycle Assessment
8.0 Limitations This LCA is for internal use and will soon be published in the BEES online system. The study was conducted following appropriate ISO standards and best practices and is intended to assist CertainTeed with understanding the life cycle impacts of their products. The inventory has been submitted to NIST for publication in the BEES online tool, and will undergo a review during that process. Since the BEES personnel will model the inventory independently in their own software tool, the exact results published in the BEES tool may vary from the results shown in this report. The results of an LCA are inherently limited by the fact that characterized environmental impacts are “potential” impacts, and not a prediction of real impacts. Actual impacts will occur based on many variables of the system and nature, and can change in real time. All data for the operation of the Buffalo plant, as well as transportation distances and modes, was collected directly from CertainTeed. Efforts were made to check the data for internal consistency and to verify data with plant personnel. Sub-metering of energy use for each critical stage in the manufacturing process would allow for more detailed analysis and is recommended.
The findings in this research are limited by the inherent uncertainty of creating a representative model through LCA. Many assumptions were made in modeling the product system with representative processes and datasets. The authors addressed the uncertainty in modeling decisions by conducting a mass balance and sensitivity analysis as the LCI model was being constructed (data verification/ validation relative to cut-off criteria and study goals). Further limitation exists due to the use of proxy materials for the composite material and the allocation methodology. All of these represent reasonably accurate approximations, but not exact amounts. While quality control was undertaken at each step in building the LCI and conducting the LCIA, uncertainty is still present in the results since the data evaluated represents only one year of manufacturing information. Detailed evaluation of multiple manufacturing plants and time periods would reduce the uncertainty. Some level of uncertainty is inherent in conducting LCA and decision making must reflect this fact.
54
CertainTeed Fence, Rail and Deck
Life Cycle Assessment
9.0 Conclusions Based on the results from the life cycle assessment, the life cycle impacts for Bufftech and Panorama are driven by the installation materials; raw materials are the main driver for the Kingston railing system and a second close driver for Bufftech and Panorama. The reduction in electricity impacts from the purchase of hydropower generated power reduces the overall impacts of global warming, acidification, criteria air pollutants, ecotoxicity, smog, and natural resource depletion. Installation material impacts can be reduced by integrating more recycled content or using aluminum instead of steel and implementing supplier sustainability requirements.. Identifying alternate uses or recycling options of the vinyl and composite products will reduce the end-of-life impacts. CertainTeed has direct control over the modes of transportation for raw materials and final products, as well as the manufacturing process. Any opportunities to reduce energy consumption in these areas will have a direct reduction in environmental impacts. It will also provide cost savings and potential competitive advantage. The composite rail has clear advantages in raw materials as the core material contains higher recycled content compared to the other products evaluated in this study. External regrind is also a recycled material and should continue to be used in the Bufftech fence and Kingston rail products. CertainTeed should evaluate the possibility of increasing the amount of material, without compromising the performance of the products. These factors contribute to overall decreased impacts in most impact categories for railing systems.
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