PAM PORTUGALSAINT-GOBAIN CONDUTAS PARA AGUA, S.ATorre Zen – Parque das NaçõesAv. D. João II, Lt. 1.17.01 – 12° piso1990084 LISBOATél. : + 351 218 925 000
PAM ROMANIA SAINT-GOBAIN CONDUCTES ParkStr. Tipografilor nr. 11-15Sector 1 – Cod 013714BUCHARESTTél. : + 40 21 207 57 25
Saint-Gobain PAM is the world leader in water cycle pipeline systems. Whilst this is a cause of great pride for all those that work with and for the company, it is also an immense responsibility.
Sustainable development lies at the heart of its corporate culture. Saint-Gobain PAM rapidly embraced the pioneering principles of sus-tainable development formulated by the Brundtland Commission. Since 1987, this international commission has encouraged today’s generations to ‘meet the needs of the present without compromising the ability of future generations to meet their own needs’.
Saint-Gobain PAM is committed to the following key fields: •TheEnvironment•Industryandtheeconomy•Social
Its state-of-the-art technologies and focus on research and development have enabled it to consistently provide its customers with quality, sustainable, reliable and ergonomic solutions.
Like communication channels, water and sewerage pipelines are infrastructures created to last for several generations. Sustainable development depends on ‘long lasting’ rather than ‘disposable’ instal-lations.
Saint-Gobain PAM has taken on board these principles and works to provide effective solutions for the environment.
More than 100 capitals and over 1000 large cities world-wide have been equipped with Saint-Gobain PAM products. Numerous hydraulic, water and sewerage projects are currently run with the support of Saint-Gobain PAM in order to boost the development of countries mainly in Latin America and Africa, but also in China and the Middle East.
SUSTAINABLE DEVELOPMENT, A COMMITMENT FROM SAINT-GOBAIN PAM
Sustainable
Environment
EquitableEconomicSocial
Bearable Viable
List of contents
Sustainable development ....................... p 3
The value of water ..................................... p 7
Quality of life ................................................ p 9
Responsible production ........................p 23 A transport synergy ...............................p 25
Commitment from Saint-Gobain PAM ......................p 27
2008 edition
1856 1866 1933 1960 1980 1995 2001 20032000 2004 2005 2008 Founding of the company Specialisation
in cast iron pipelinesIntroduction of the centrifugal
pipe casting processDuctile iron pipes invented INTEGRAL for sewerages Anchored systems NATURAL
for the supply of potable waterIRRIGAL
for irrigation networksPLUVIAL for rainwater TAG 32
for gravity sewerage mainsURBITAL
for reuse waterBLUTOP
for small diameter potable water networks
www.pamline.comDevelopment that lasts
Saint-Gobain PAM’s overriding mission is to provide actions for the entire water cycle
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The concept of sustainable development prompts an in-depth reflection on the consumption of water, its treatment and consequently its protection. The amount of fresh water used totals almost 4,430 km3 a year, 2,300 km3 of which are for consumption. An informed, responsible and environmentally-friendly approach is essential in order to guarantee renewable and reusable water resources. Furthermore, through its research into pipelines, Saint-Gobain PAM works to improve the various uses of water and to narrow the gap between usage and consumption.
According to the World Health Organisation, around 1.1 billion people in the world have no access to potable water and 2.4 billion have no sewerage systems. These major deficiencies in the water cycle have a dramatic impact on public health: 3.2 million people, most of them children, die from hygiene-related diseases each year.
The rivers and groundwater that constitute our traditional water resources require urgent conservation attention, yet it is also essential to work towards new and effective long term solutions. Indeed, the growth of urban areas and the population boom require new water treatment methods, and also naturally imply additional domestic, agricultural and industrial demands.
As a result of its long-standing industrial experience and total commitment to water cycle products, Saint-Gobain PAM is asked by customers and partners to take part in new water recycling projects, as well as desalination plants and recharging of underground aquifers as provision for potential future shortages, etc.
Its involvement in local government projects has made Saint-Gobain PAM aware of the need for more efficient and cost-effective management schemes, which respect the diversity of usage whilst guaranteeing the ecosystem (water supplies, treatment of used and rain water, the fight against fires, irrigation, etc.).
THE VALUE OF WATER
Action for the entire water cycle
Wallowa lake, State Park ,Oregon (USA).
• Saint-Gobain PAM is totally committed to the supply of water cycle products.
• Each year, its voluntary innovation policy takes the form of new watertight, sustainable and environmentally-friendly solutions.
• A member of local groups, Saint-Gobain PAM is committed to working for solutions for the supply and distribution of water, sewerage, irrigation and the fight against fires that provide greater protection for our ecosystems. H
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Laying of a pipeline to supply potable water
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• Guaranteed potability of the water distributed through naturally watertight ductile iron pipes, preventing any leakage of this resource.
• Meticulous selection of materials (coatings, joints, repair products, lubricants), certified by France’s ACS, Germany’s DVGW, UK’s WRAS and DWI, meeting the sanitary standards for the production of water supply and distribution products.
• Promotion of top quality reliable products allowing for the promotion of tap water consumption.
• Mineral interior pipe coatings based on cement mortar produced using potable water for optimum sanitary conditions.
• INTEGRAL and TAG 32 ranges for watertight sewerage networks to prevent pollution of soil and to allow for the treat-ment of all waste water.
QUALITY OF LIFEPreserving
the quality
of water
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Blue Lagoon (Iceland).
The performance in terms of watertightness and the coatings of Saint-Gobain PAM’s ductile iron pipeline systems guarantee the sanitary quality of water during transportation and distribution.
Constant attention is given to the quality of the water destined for human consumption produced by treatment plants. This applies both to the protection of the catchment areas and work on treatments including the regular lowering of potentially pathogenic micro-organisms and che-mical products.
The challenge for Saint-Gobain PAM is to provide the transporta-tion and distribution systems that guarantee this water reaches consumers in optimum condition. The careful choice of the materials used for pipelines in contact with water guarantees maximum quality and standards throughout the network. These materials are selected by the scientists at the Saint-Gobain PAM laboratories in close collaboration with the very best suppliers.
Strict compliance with national regulations and current legislation is gua-ranteed thanks to an exhaustive quality assurance system based on ISO 9001 standards.
The company is equally committed to supplying pipeline systems that are not only leak-free today but will continue to be so in 100 years’ time! Ductile iron pipeline joints are renowned for their watertightness. Saint-Gobain PAM has further enhanced this characteristic by using even more durable elastomer joints that are resistant to the oxidising agents present in water and prevent the growth of micro-organisms on contact.
Ductile iron sewerage networks also require joints offering optimum performance in terms of watertightness in order to eliminate waste water leakages that could potentially contaminate the soil, groundwater and attack neighbouring pipelines.
Saint-Gobain PAM works with government authorities, water dis-tributors and laying companies in order to implement ongoing improvements to its products.
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Seljalandsfoss Waterfall (Iceland).
Saint-Gobain PAM’s pipeline systems are designed to last for more than 100 years.
As proved by many studies, sustainable development depends on ‘long lasting’ rather than ‘disposable’ installations. Saint-Gobain PAM has taken on board these principles and works to provide effective solutions for the environment.
The average annual rate of potable water pipeline renewal stands at around 0.6 to 0.7%. This means that based on current investment levels, the pipelines currently being laid will be required to last around 150 years!
The durability of ductile iron works has been known for decades. Indeed, there are many hydraulic networks with cast iron pipelines that were laid over 100 or even 150 years ago, and which continue to provide a satisfactory service. Replacement of these pipelines is not yet required.
Apart from the intrinsic qualities of ductile iron, this durability is also attributable to the quality of the exterior coatings, which provide protection against soil aggression, as well as the interior ones, which resist water or effluent reactivity.
For decades, the research staff at Saint-Gobain PAM’s laboratories has worked painstakingly to provide state of the art protective coatings. This work covers both theoretical and practical aspects, including laboratory experiments and, above all, exhaustive on-site testing.
To this end, Saint-Gobain PAM owns testing grounds in the Bay of Mont-Saint-Michel, which it uses for trials on new coatings under the most aggressive soil conditions.
Interior linings play an equally important role in ensuring durability. Saint-Gobain PAM has developed centrifuged cement mortar-based mineral linings with blast furnace cement for potable water and aluminous cement for sewerage which have become worldwide leaders. The company also offers an additional range of linings, such as epoxy for fittings, spigots and the interior of TAG 32 pipes, or the brand new Ductan for Blutop pipes used for smaller diameter water distribution.
DURABILITY RELIABILITY
Producing
systems
that last
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Zinalium coatings, made from a zinc and aluminium alloy, considerably increase the pipeline lifetime.
• In certain cities around the world, such as a Paris, cast iron pipelines that were laid 150 years ago are still in service.
• Saint-Gobain PAM ductile iron pipelines have been laid in more than 100 capital cities worldwide.
• Emerging nations such as China, India and Russia, etc., are opting to use ductile iron pipelines for their supply networks.
• Towns and cities choose ductile iron pipeline systems in order to reduce leakage rates.
• The Zinalium coating, made from zinc and aluminium and used in the Natural and Blutop ranges, at least doubles the lifetime of ductile iron pipes.
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Supplying potable tap water, collecting and treating waste water are global challenges that require the very finest technologies.
There is an urgent worldwide need for potable water supplies, as well as the collection and treatment of waste water in accordance with specific local and environmental conditions. This need is particularly evident in emerging nations. As water is an essential resource, the solutions must be based on an environmentally friendly approach. Care for the environment, active on site collaboration between local teams and Saint-Gobain PAM engineers and technicians, and a dialogue that takes into account the future management of the projects carried out, are all values and principles that we apply on a daily basis.
Right from the drawing board stage of any project, Saint- Gobain PAM provides the various groups involved with optimum solutions aimed at improving the performance of the networks to be laid and facilitating their installation in areas where access is often difficult. The vast range of Saint-Gobain PAM products provides solutions capable of overcoming difficulties in terms of hydraulic performance and pipeline protective coatings in even the harshest land conditions such as the Persian Gulf (characterised by corrosive soils, high temperatures and solar radiation, etc.).
An example of this is the Doha North Sewage Treatment Works project in Qatar, which complies fully with Saint-Gobain PAM’s sustainable development principles and values. Indeed, Qatar is the first member state of the Golf Cooperation Council to undertake to reduce its greenhouse gas emissions between now and 2012. Its environmental policy aims to preserve its natural resources whilst guaranteeing industrial development. Set to become operational in 2010, the Middle East’s largest waste water treatment and reuse plant will allow for the irrigation of green spaces on a small island that is home to an important nature reserve for oryx, gazelles and migrating birds.
The Doha North treatment plant will be eco-friendly and will generate high quality reusable water. It will also be equipped with an odour control system.
THE FUTURE IS WATER FOR ALL
Sharing
our experiences
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Playa Matapalo (Costa Rica).
Ductile iron fittings at a site in Mauritania.
Site meeting in Panama.
• Supply of pipeline systems to Algeria, Libya, Mauritania, Senegal, Nigeria, Palestine, Qatar, Pakistan, China, Peru, Brazil, Mexico, etc., to provide quality water supplies and long-lasting sewerage systems.
• Delivery of pipelines for the Doha North treatment plant in Qatar that will transport 439,000m3 of water a day, tripling the existing capacity. The plant will recycle water for a population of 900,000.
• Supply of around 200 km of pipelines for the Aftout Essahli project in Mauritania, within the framework of the national strategy for the fight against poverty.
• The Urbital range promotes the use of recycled water.
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The teams of engineers and technicians at Saint-Gobain PAM work to reduce the energy consumption of the equipment it supplies to hydroelectric power stations.
Hydroelectric energy is a renewable energy that has been in use for decades. It currently makes up 16.6% of the world’s electricity production, and 89% of the electricity generated using renewable resources, with an annual growth rate of 2%.
In addition to large dams, it is also possible to produce decentralised electricity that does not spill any waste into the water or generate contaminating gases. Indeed, compared with a traditional combustion power station, each year, a 1MW hydroelectric power station will prevent the emission of around 2,500 tons of CO2 into the atmosphere. 1MW is enough to meet the electricity needs of around 630 homes. Today’s mini power stations are designed to respect natural water flows and the facilities are built to blend into the landscape. The pressure pipes that supply the water to the turbines are generally made from ductile iron and run underground. Various European countries have adopted hydroelectric technology in order to reach the 20% target set by the European Union for 2020.
In addition to the fundamental need for the development of renewable energies, energy and material economies boast a vast potential for action in terms of sustainable development.
Saint-Gobain PAM renews and implements ongoing improvements to its production processes in order to optimise energy consumption. Special attention is given to its buildings where the ambitious long-term objective is to cut energy consumption by 4.
The optimisation of product weight is also of considerable interest, as it allows for reduction in energy consumption not only during production, but also during the transportation and installation stages.
ENERGIES FOR RENEWAL
Economising
for sustainability
Construction of a pressure pipeline, a Norwegian project.
• Saint-Gobain PAM participates actively in the development of micro hydroelectric power stations, especially
in Norway and Austria.
• The use of charcoal from the Saint-Gobain PAM plantations to produce coke for use in Brazilian blast furnaces.
• In just 10 years, Saint-Gobain PAM has cut its energy requirements by 30%.
• The objective is to cut energy consumption in buildings by 4 between now and 2040.
• Energy consumption during transportation is dependent on the reduction of unnecessary product weight.
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100% of ductile iron materials can be permanently recycled without losing any of their performance properties.
Ductile iron is essentially an alloy made from iron, carbon and silicon – elements which are found in large amounts in the earth’s crust, which is made up of around 5% iron and 26% silicon. Known worldwide reserves of pure iron stand at around 230 billion tons, which at current consumption rates guarantee supplies for many years to come.
Yet iron, as scrap iron and a waste metal, also boasts the world’s highest material recycling rate, which stands at around 67%. The iron recycling sector is well-organised on a local scale, ensuring efficient, professional and economically feasible collection methods. This sector is enjoying steady growth and the amount of scrap iron used worldwide exceeds 400 million tons a year.
Ductile iron pipeline systems made from recycled products offer identical levels of performance to those made from iron ore. Also worthy of mention is the fact that recycled iron can be used for the production of both sewerage and potable water distribution systems.
Saint-Gobain PAM works hard to develop high performance products, limiting the amount of materials used to that which is strictly necessary, in accordance with current regulations. The new Natural, TAG 32 and Blutop ranges represent major breakthroughs in the reduction of raw materials, whilst at the same time guaranteeing optimum performance levels.
In addition, Saint-Gobain PAM has implemented a policy aimed at reducing water consumption in its factories through developments such as the Archimedes process for lining the pipe interiors with cement.
AT THE CORE , OF NATURAL RESOURCES
Taking
advantage
of scrap iron
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Cast iron pipe laid in the late 17th century during the construction of Versailles Palace, and which is destined for recycling.
• 100% of ductile iron materials can be permanently recycled.
• Following recycling, ductile iron can be used to produce pipelines for both potable water and sewerage.
• Integrated on site energy management allows for consumption to be reduced.
• The new Archimedes process, which consists of coating the pipe interiors, requires less water and generates less silt. Hig
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The fountains at Versailles Palace (France), an attraction made possible thanks to cast iron pipelines.
2008 edition
Project (Panama).
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Pipeline project to supply water to the cities of Algiers and Tizi-Ouzou
The sturdiness of ductile iron pipelines allows for the reuse of natural soil for backfilling trenches.
IN CONTACT WITH THE EARTH, NATURALLY
Reusing
natural soils
Laying pipelines may require the excavation of large amounts of earth, which may be as much as 5 to 10 times the volume of the pipeline laid. All too often, this earth is dumped and replaced with imported backfill.
Taking account of all phases of the operations, ranging from production to installation to the entire life cycle of the installation, is essential in order to ensure the correct approach to sustainable development. The environmental impact of the laying phase is of particular importance. Disposing of the excavated earth and importing backfill is restrictive, costly and impacts the environment. Certain studies have shown that the environmental impact during laying is far higher than during the manufacturing phase. This has led to an analysis of the life cycle that is currently in progress.
A series of simple actions have already been implemented in order to reduce native soil materials as far as possible, thereby considerably reducing the need to excavate the natural environment, dumping and unnecessary lorry traffic.
The sturdy and solid nature of ductile iron pipelines, together with their resistance to cracking and the active properties of the coatings, allow for the use of native soil in most cases (following the clearing of larger stones) as a covering for the laying bed.
Saint-Gobain PAM has also developed product lines adapted to trench-free laying processes, particulalry Horizontal Directional Drilling. This is possible thanks to the development of the new anchoring systems featured in our Universal Ve range. As a result, several tens of kilometres of ductile iron pipes are laid in Europe each year without the need for trenches. This technique is experiencing rapid expansion.
• Promotion of the reuse of natural backfill instead of filler materials, thank to the resistance and sturdiness of ductile iron pipelines.
• Limited inconvenience associated with laying extensions during the products lifetime.
• Design of systems that are faster to lay.
• Active promotion of trenchless laying technologies whenever appropriate. Hig
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Innovation based on life cycle analyses and the eco-conception, allows for the reduction of the impact on the environment.
ONGOING INNOVATION
Innovation
to protect
the environment
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Pont du Gard (Roman aqueduct) - France.
PAM KAMELEO variable angle fitting
• CO2 emissions from the Natural range are around 20% lower than the classic range.
• The new Blutop and TAG 32 ranges allow for a reduction of between 30% and 50% in the amount
of materials used.
• Anchoring system technologies have allowed for the elimination of heavy and voluminous concrete blocks,
thereby reducing the amount of space required underground.
• Laying ergonomics is taken into consideration right from the design stage.
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The eco-conception is based on in-depth analyses of the life cycles of the major product lines. This falls within the framework of the ISO 14 001 Standard, and is made up of four stages: defining objectives; analysing the life cycle; assessing the impact on the environment; and research into improvements.
Saint-Gobain PAM has worked with leading independent life cycle analysis (LCA) experts on its major product lines, covering their installation and maintenance throughout their useful lives (more than 100 years). These analyses will be the object of PCR (Product Category Rules) and environmental statements which provide reliable details of the environmental impact of our products.
Saint-Gobain PAM works to reduce atmospheric and waste emissions, assessing products in order to guarantee sustainable performance that meets customer needs. By staying one step ahead of future environmental regulations, Saint-Gobain PAM aims to think about the future today.
Within the space of just fifteen years, the company has achieved a 20% reduction in the weight from the ductile iron pipes that made up the old generation of products to the new Natural range. This revolutionary innovation has been achieved without reducing the excellent safety coefficient of our products, which offer a 3x factor of resistance to bursting (i.e. a minimum resistance of 120 bar for Class 40 Natural pipes). In addition, energy and raw material consumption per metre of pipeline and year of exploitation has been cut by four since 1990.
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RESPONSIBLE PRODUCTION
Constant
progress
Pipe quality assurance work in Pont-à-Mousson (France).
Its exhaustive know-how of water cycle products enabled Saint-Gobain PAM to rapidly identify and control the environmental issues involved in its industrial processes. In France, 19% of investments in materials go to projects relating to health and the environment. Eighty percent of Saint-Gobain PAM’s waste products are currently valorised (i.e. value recovered in some way), and the aim is for that figure to rise to 100%. In Europe, production is balanced between those subsidiaries using iron ore and those that opt for recycled scrap iron. Internal recycling of metal waste from the production process stands at 100%.
In order to take this commitment even further, all the group’s production sites are currently working to obtain ISO 14001 Standard certification, and the aim is for this process to be completed by 2010. Numerous sites have already been certified, and a large number of projects have already taken shape for 2008 and 2009. The targets set are ambitious in terms of the results expected. This certification is unquestionable proof of the existence and efficiency of Saint-Gobain PAM’s environment management system. These international regulations allow for the assessment of factory activity in terms of the environment, as well as providing proof of the company’s commitment to implementing environmental protection strategies.
Obtaining the ISO 14001 Standard Certificate is based on the involvement and maximum commitment of all those that work with and for Saint-Gobain PAM on the various sites. The certificate covers both the product design and production phases.
The ISO 14001 Standard Certificate is in line with the company’s long-standing concern for quality in terms of the design, manufacturing and commercialisation of its products, as shown by its ISO 9001 certificate. Thus, Saint-Gobain PAM’s policy is to apply ongoing improvements to its range of products in order to guarantee maximum customer satisfaction. The teams at Saint-Gobain PAM analyse their product and service needs, and then define the specifications necessary to meet those demands whilst at the same time ensuring maximum protection for the environment. They industrialise the production methods suitable for manufacturing the products, purchase the materials and manufacture in accordance with the defined and controlled specifications, and finally guarantee the delivery and provision of the products and services within the agreed deadlines.
In order to secure ongoing improvements to performance in all areas, the teams assess the results of their actions, quantifying and analysing any discrepancies with the objectives set, defining and applying corrective actions and checking their efficiency. Saint-Gobain PAM aims to become the world leader in its field and its quality assurance policy reflects this objective.
The challenge for Saint-Gobain PAM is to guarantee constant progress in its industrial processes in order to reduce energy consumption and cut CO2 emissions.
Graphite nodules seen under an electronic microscope.
• All plants will be ISO 14001 certified by 2010.
• In Europe, production is balanced between the production of iron using iron ore and recycled scrap iron.
• 80% of all waste materials are valorised. The objective is for 0% non-valorised waste.
• 19% of Saint-Gobain PAM’s investments in France are spent on health and the environment. Hig
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Example of a reduction of materials in a PAM product: the mass evolution in a DN 100 pipe.
Mass (in kg)
1980 1990 2000 2010 Blutop
120100
80604020
0
2008 edition
DN 2000 pipe train, Fontainebleau (France).
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Saint-Gobain PAM uses modes of transport that emit low levels of CO2 in order to supply its factories with raw materials and deliver its products to its customers.
Saint-Gobain PAM has acquired outstanding skills and know-how in the transportation of pipelines, and is capable of meeting both its national and international requirements over considerable distances.
It has systematically optimised its transport systems by combining several means (waterways, sea, rail and road). Excellent project planning enables the products to be delivered in optimum conditions and at the best rates, reducing transport difficulties to a minimum.
Localised production sites on several continents (Europe, Latin America, Asia and Africa) allow for optimum solutions, and reduce the distances to be covered.
Both Saint-Gobain PAM’s production and distribution sites are generally interconnected by rail and waterways. In France, for instance, the site in the Lorraine region at Pont-à-Mousson receives most of its raw materials via rail or waterway. The products manufactured there are then loaded onto trains or barges, and then, if necessary switched to a vessel at a port.
SYNERGYA TRANSPORT
Prioritising
our own
transport
systems
Pipes being loaded in Antwerp Port.
• 65% of the manufactured products are transported by rail, waterways or sea:1 train = 30 lorries 1 barge = 20 lorries
• The Blutop range can be manually transported and assembled, thereby reducing the need for vehicles on site.
• The reuse of natural backfill drastically reduces lorry rotation and the need for filler materials.
• The production plants are carefully selected in accordance with the delivery sites.
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Saint-Gobain PAM is committed to the challenges of sustainable development at each stage of the design, production and commercialisation processes.
SAINT- GOBAIN PAM
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The principles and values defended by Saint-Gobain PAM are based on the responsible use of resources and materials, as well as a firm professional commitment to respect for the environment and health and safety in the workplace. Internally, a constant flow of communication with all its workers and collaborators allows for the smooth implementation of positive corporate changes whilst encouraging personal career development. The flow of information and two-way communication favours professional achievements within the general interests of the company.
In addition, the integration of the disabled into the work-force is one of the values applied at Saint-Gobain PAM. In addition to the natural respect for the individual, this principle enhances the motivation of all its employees, building up a sense of cohesion.
The concern for sustainable development is present in each of the decisions made and is reflected in the working conditions and remuneration: a secure environment, the identification and prevention of risks, and the assessment of possible hazards.
Saint-Gobain PAM contributes actively to the needs and demands of sustainable development by involving all its collaborators and employees, transmitting values of responsibility, transparency, creativity and innovation. The application of the EHS Charter (environment, hygiene in industry and health and safety) is a direct response to its respect for the law and health and safety in the workplace.
• Social policy based on 3 principles:- Respect for people,- Respect for health and safety at work,- Respect for employee rights.
• Recruitment of more than 550 new collaborators in France between 2007 and 2008.
• 3.5% of the payroll is dedicated to training (50,000 hours).
• Integrated Work Assistance Centre for the insertion of the disabled.
• Saint-Gobain has signed up to the UN Global Compact.
