Environmental Product Declaration · the VMZINC company, statistical data from the Metal Trade...

Declaration number EPD-UMC-2010211-E Institut Bauen und Umwelt e.V. www.bau-umwelt.com

VMZINC® from Umicore Bausysteme GmbH

- Surface:

QUARTZ-ZINC®, ANTHRA-ZINC®-

Environmental Product Declaration a c c o r d i n g t o I S O 1 4 0 2 5

http://www.bau-umwelt.com/�

Brief version

Environmental Product Declaration


Institut Bauen und Umwelt e.V.

www.bau-umwelt.com

Programme holder

Umicore Bausysteme GmbH

Gladbecker Straße 413

D-45326 Essen

Declaration holder

EPD-UMC-2010211-E Declaration number

QUARTZ-ZINC® / ANTHRA-ZINC

This declaration is an environmental product declaration in accordance with ISO 14025 and describes the specific environmental features of the construction products outlined here from Umicore Bausysteme GmbH in Germany. It intends to promote the development of construction which is compatible with the environment and health. This validated declaration discloses all of the relevant environmental data.

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This declaration is based on the “Metals for Buildings 2009-09” PCR document.

Declared construction products

This validated declaration entitles the holder to bear the Institut Bauen und Umwelt e.V. symbol. It applies exclusively to the products referred to for three years from the issue date. The declaration holder is liable for the underlying details and documentation.

Validity

The declaration is complete and comprises in detail: - physical construction details, - details on base materials and material origin, . description of the product manufacturing process, - information on product processing, - data on utilisation status, extraordinary effects and re-use phase - Life Cycle Assessment results - documentation and test.

Content of the Declaration

2nd Issue date February 2010

Signatures

Prof. Dr.-Ing. Horst J. Bossenmayer (President of IBU)

This declaration and the regulations upon which it is based have been tested by an independent Committee of Experts (SVA) in line with ISO 14025. Testing the Declaration

Signatures

Prof. Dr.-Ing. Hans-Wolf Reinhardt (Chairman of the SVA) Dr. Frank Werner (Auditor appointed by the SVA)

Brief version



Metal sheets and coils made from QUARTZ-ZINC® and ANTHRA-ZINC® consist of rolled VMZINC®

Product description , a titanium zinc allow in accordance with DIN EN 988 based on electrolytically produced refined zinc of high purity level 99.995% Zn (Z1 zinc) in accordance with DIN EN 1179 and low alloy components of titanium and copper and aluminium. This declaration applies to ANTHRA-ZINC (pre-weathered anthracite) and QUARTZ-ZINC (pre-weathered light grey) surface qualities.

QUARTZ-ZINC® and ANTHRA-ZINC®

• Roofing (e.g. standing seam roofing, batten roof system, diamond roofing etc.)

sheets and coils are used in numerous construction applications:

• Facade applications (e.g. angled standing seam cladding, reveal panels, cassettes, large diamonds etc.)

• Flashings, coverings (e.g. wall protectors, roof edge fascia, wall coverings, etc.)

• Roof drainage systems (guttering, pipes and accessories)

• Ornaments under the brand name of "Ateliers d’Art Français“

Area of application

The Life Cycle Assessment was carried out in accordance with DIN ISO 14040 ff. Specific data from the VMZINC company, statistical data from the Metal Trade Association and the "GaBi 4" database was used as the base data. The Life Cycle Assessment was carried out for the products’ manufacturing phase taking consideration of all upstream chains such as raw material extraction, energy provision and transport (“cradle to grave”). The manufacturing and disposal and/or thermal utilisation of packaging was also taken into consideration.

The utilisation phase is not examined.

In the end of life phase the processing of a titanium zinc sheet was modelled in a remelting furnace. The resulting credit of zinc obtained from this is calculated using a primary zinc manufacturing data record.

Life Cycle Assessment Framework

QUARTZ-ZINC® / ANTHRA-ZINC®

Analysis factor

Unit per kg Total

Manufacturing and recycling

Manufacturing Recycling potential

Non-regenerative primary energy [MJ] 15,65 51,39 -35,74

Regenerative primary energy [MJ] 1,52 8,25 -6,73

Global Warming Potential (GWP 100) [kg CO2 0,70 -equiv.] 3,41 -2,71

Ozone Depletion Potential (ODP) [kg R11 equiv.] 2,06E-07 4,73E-07 -2,67E-07

Acidification potential (AP) [kg SO2 4,69E-02 -equiv.] 6,78E-02 -2,09E-02

Eutrophication Potential (EP) [kg PO4 8,30E-03 -equiv.] 1,05E-02 -2,21E-03

Photochemical Ozone Creation

Potential (POCP) [kg ethene equiv.] 1,98E-03 3,09E-03 -1,10E-03

Results of the Life Cycle

Assessment

Created by: PE INTERNATIONAL GmbH, Leinfelden-Echterdingen

In addition, the following documentation and tests are depicted in the Environmental Declaration:

• Atmospheric corrosion and surface-related loss of mass (erosion), Measuring of corrosion rates and erosion over a trial period of 1 year (1998-1999)

Documentation and tests

Environmental Product Declaration QUARTZ-ZINC® / ANTHRA-ZINC® Page 4

Product group Metals for buildings Created Declaration holder: Umicore Bausysteme GmbH 02-02-2010 Declaration number: EPD-UMC-2010211-E

Area of applicability This environmental product declaration refers to QUARTZ-ZINC®/ANTHRA-ZINC® sheets and coils made from VMZINC®

- titanium zinc from the VMZINC factory in Viviez (France).

1 Product definition

Product definition

QUARTZ-ZINC®/ANTHRA-ZINC® sheets and coils consist of rolled VMZINC® - titanium zinc. Rolled VMZINC®

VMZINC

is a titanium zinc alloy with copper and titanium with optimal mechanical and physical properties for applications in construction, in particular regarding mechanical resistance and resistance against creep deformation. This declaration applies to ANTHRA-ZINC (pre-weathered anthracite) and QUARTZ-ZINC (pre-weathered light grey) surface qualities.

®

Application

is an alloy in accordance with DIN EN 988 based on electrolytically produced refined zinc of a high purity level 99.995% Zn (Z1 zinc) in accordance with DIN EN 1179 and low alloy components of titanium, copper and aluminium.

QUARTZ-ZINC®/ANTHRA-ZINC®

• Roofing (e.g. standing seam roofing, batten roof system, diamond roofing etc.)

-sheets and -coils are used in numerous construction applications:

• Facade applications (e.g. angled standing seam cladding, reveal panels, cassettes, large diamonds etc.)

• Flashings, coverings (e.g. wall protectors, roof edge fascia, wall coverings, etc.)

• Roof drainage systems (guttering, pipes and accessories)

• Ornaments under the brand name of "Ateliers d’Art Français“

Product standard / Approval

DIN EN 1179, DIN EN 988, DIN EN 612

Quality assurance

Internal monitoring by the manufacturer. Quality management system in accordance with ISO 9001. Quality checks in accordance with PREMIUMZINC criteria. Production sites: regular quality audits in accordance with KOMO standard. Environmental management in accordance with EN ISO 14001.

Delivery status, features

Pre-weathered QUARTZ-ZINC® and ANTHRA-ZINC® offer other surface designs. They are produced by immersing the bright-rolled VMZINC®

Right from the start QUARTZ-ZINC

into a solution which changes the metal's crystalline surface structure up to a depth of about a µm. This treatment takes place by phosphating and leads to a permanent chemical change of the metal's surface structure.

®

ANTHRA-ZINC

has a similar look to the natural patina of bright-rolled zinc.

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Dimensions: Panels: 1000 x 2000 mm, 1000 x 3000 mm; has a dark grey, anthracite coloured surface.

Coils with following blanks: 200 mm / 250 mm / 280 mm / 333 mm / 400 mm / 500 mm / 600 mm / 670 mm / 1000 mm

Thickness [mm]: 0.65 mm to 1.5 mm Weight: 4.7 kg/m2 (t=0.65 mm) to 10.8 kg/m2 (t=1.5mm)

Thickness [g/cm³] = 7,2



Structural properties

Melting point: approx. 420 °C Thermal conductivity: 110 W/(mK) Electr. conductivity: 17 mS/m Coefficient of expansion • t: 2.2 mm/m at 100K an 10 m sheet length Strength: (all values measured lengthways) Tensile strength: 152 < Rm < 190 N/mm² (PREMIUM ZINC) 0.2 %- yield point: 110 < Rp 0.2% < 150 N/mm² (PREMIUM ZINC) Tensile stretch: A50 • 35 % Elasticity module: E • 90 000 N/mm2 Vickers hardness: HV > 45 (PREMIUM ZINC)

2 Base materials

Base materials Preliminary products

Consumables / Additives

Table 1: Base materials for the manufacturing of one kg of titanium zinc sheet

Base materials in mass-% for one kg of titanium zinc

Component VMZINC titanium zinc

Refined zinc (the zinc used has a purity of 99.995% (Z1 with limited Pb and Cd in accordance with DIN EN 1179))

< 99,835%

Copper 0,08 - 0,2%

Titanium 0,07 - 0,12%

Aluminium < 0,015%

Consumables

• Ammonium chloride (smelting): 0.4 kg/t zinc

• Roller emulsion (rolling): 0.66 kg/t zinc

• Nitric acid (pre-weathering): 7.3 g/kg

• Phosphoric acid (pre-weathering): 1.74 g/kg

• Sulphuric acid (pre-weathering): 0.87 g/kg

• Zinc phosphate (pre-weathering): 0.6 g/kg

Material definitions

The alloy components copper, titanium and aluminium optimise the mechanical, technological and physical properties of the zinc for applications in construction.

Copper Mechanical strength

Titanium Creep strength

Aluminium Smelting and casting process (protection against zinc oxidation)

The above mentioned consumables have different jobs during the production process.



Ammonium chloride

Smelting Used to separate impurities

Roller emulsion Rolling Used as lubricant during the rolling process

Acids Pre-weathering Used for chemical etching

Zinc phosphate Pre-weathering Used for phosphating

Pre-weathering by phosphating produces a surface which is very close to the naturally formed patina of bright-rolled zinc.

Harvesting raw materials and origin of materials

Most zinc mines can be found in North and South America, Asia and Australia (not so many in Europe and Africa). Zinc ore is mined in underground mining and in opencast mining. 80% of the zinc ore used in the zinc industry comes from underground mining and 20% from opencast mining. Most zinc mining companies are members of the International Zinc Association (IZA), which means they have signed the IZA Charter (2) on Sustainable Development and mine zinc ore according to the respective principles. The overwhelming majority of the copper and titanium used are secondary raw materials. All aluminium used consists of secondary raw materials.

Regional and general availability of raw materials

The current zinc ore reserves are estimated to be 1,900 mill. tons worldwide. These estimates are based on current geological knowledge and exploration technology. With a global annual zinc consumption of approx. 10 mill. tons (30% of this recycled zinc) this results in a zinc supply for about 300 years.

3 Product manufacturing

Product manufacturing

Zinc extraction: The zinc ore is ground using gravity and elutriation in order to obtain a fine-grain concentrate. With this process the ore is ground and diluted with water. The deposition of the metal takes place by adding flotation agents. Rolled VMZINC is produced by using a electro-metallurgical smelting process. The first step in the process is to remove the sulphur from the concentrate. This is achieved by roasting and sintering. The concentrate is heated in a furnace at over 900°C to calcinate the zinc sulphate into zinc oxide. At the same time the sulphur reacts with the oxygen resulting in sulphur dioxide, which is then converted into sulphuric acid in the acid system which is usually found in the molten zinc. During the leaching process the zinc oxide is dissolved into a thin sulphuric acid solution, which is fed back from the electrolysis cells to obtain an aqueous zinc sulphate solution. Iron impurities are also dissolved and with the presence of zinc oxide or possibly also ammonia turn into either jarosite or goethite. Jarosite and goethite are generally disposed of into sedimentation tanks. Cleaning is usually carried out by adding zinc dust to zinc sulphate solution. Cleaning the leachate leads to the precipitation of cadmium, copper and cobalt metals. During electrolysis the cleaned solution is electrolysed between lead alloy anodes and aluminium cathodes. The highly pure zinc forms deposits on the aluminium cathodes and is removed, dried, smelted and cast into highly concentrated zinc bars (99.995% zinc). Manufacturing of rolled zinc The manufacturing of rolled VMZINC takes place in 5 stages: 1. Pre-alloying: An alloy comprising of copper, titanium and aluminium is prepared at 650°C in an alloy furnace. This master alloy is put together with the refined zinc in a second smelting furnace.



2. Smelting: Refined zinc cathodes and ingots are smelted in the first induction furnace at 500°C and then put together with the master alloy in a second smelting furnace. The finished alloy is fed into the casting furnace. This loads the continuous casting machine at 500°C. 3. Casting and cooling: The molten metal is transferred into a continuous casting machine to harden there into the form of an approx. 12 millimetre thick and one metre wide continuous cast strand. The controlled cooling process in the system guarantees a fine, homogenous grain size. 4. Rolling: The cast strand is rolled into the desired thickness in three to five rolling operations. In the course of this process the temperature, rolling speed and degree of reduction are constantly monitored and adapted to achieve the desired mechanical properties and dimensions. 5. Stretching and cutting: The final stages include stretching and cutting the rolled zinc into sheets and coils in the desired dimensions and weights. 6. Pre-weathering: Pre-weathered QUARTZ-ZINC® and ANTHRA-ZINC® are produced from bright-rolled VMZINC® through surface treatment. Pre-weathering is a continuous, multi-stage surface treatment process consisting of etching, phosphating, rinsing and drying. QUARTZ-ZINC® surface protection is achieved by a film of oil, ANTHRA-ZINC®

Health protection in manufacturing

surface protection is achieved by applying a thin organic (transparent) coating.

Measures for avoiding health risks/problems during the manufacturing process: During the whole manufacturing process there are no health protection measures required beyond the legally established industrial protection measures for tradespeople.

Environmental protection in manufacturing

All production sites for Umicore construction products are certified in accordance with ISO 14001. Measures for reducing environmental pollution triggered by the manufacturing process: Air: The process air is cleaned to below the officially set limits using suitable emission protection measures (filter systems). Water/Ground: No contamination of water or ground. The casting process' cooling works with a closed water cycle. Waste water resulting from the pre-weathering process is cleaned in a neutralisation plant found at one of the production locations. Noise: As a result of sound protection measures taken, sound level measurements have shown that all values established inside and outside the production sites lie way below the values required by public law.

4 Product processing

Processing recommendations

General principles: • VMZINC® must be stored in a dry and ventilated place. This also applies to

building site storage as well as for parts stored temporarily at the installation site. Coils are to be stored on pallets, so that moisture cannot penetrate into them (later water stains). Transport may only be carried out by enclosed vehicles. If titanium zinc surfaces are covered with films, make sure that the surfaces are well ventilated. Wet covering films may not come into direct contact with the titanium zinc surfaces to be covered. Titanium zinc which is wet from water may also not be directly covered.



• The material is to be processed without tension. • Take into account the material's temperature-related changes to length with

installation and processing. • If for compelling reasons the titanium zinc work is carried out during the cold time

of year, special measures are required with folding which incur additional costs. This must be agreed with construction management. With metal temperatures below 10°C and rapid deformation, whole batches have to be warmed up to prevent cracks forming. This particularly applies to connections, for example crimp folds and 180° handling.

Assembly of titanium zinc with other metals: Electrolytic corrosion can occur when assembling together with different metals, if the metal (-part) of the higher potential is arranged above it in the water's flow direction. With the presence of damp or moisture, damage can occur if titanium zinc components come into contact with copper or unprotected (non galvanized) steel due to an electrochemical reaction. The direct proximate assembly of copper and titanium zinc components is always to be avoided. Assembly of titanium zinc with other building materials: If titanium zinc components (roofs/facades) are to come into contact with precipitation water from unprotected bituminous roofing, these should be provided with protective coatings, as otherwise you can reckon with so-called "bitumen corrosion". Detailed processing information like for example types of fixings, deformation and joining techniques can be found in the corresponding information material from Umicore Bausysteme GmbH.

Industrial safety Industrial safety and health protection measures: With the processing/installation of VMZINC®

Environmental protection

products no other health protection measures are required beyond the usual industrial safety measures (like e.g. protective gloves).

Environmental protection measures:

No significant environmental pollution is triggered by the processing/assembly of the named products. No special measures need to be taken to protect the environment.

Residual materials

Residual materials and packaging:

Any VMZINC®

Rolled zinc products are 100% recyclable. In Europe there is an extensive network which takes back zinc waste from building sites and recycles this for a huge variety of applications.

residual materials and packaging on the building site must be collected separately. The specifications outlined by local disposal authorities and the information provided in section 6 “Re-use phase” must be taken into consideration when disposing of residual materials.

Packaging The packaging materials used are PE films, corrugated board and steel bands. Transportation is carried out on wooden pallets. Packaging material for 1kg of QUARTZ-ZINC® and ANTHRA-ZINC® corrugated board (0.005 kg), wood (pallets) (0.03 kg) and plastic film (0.001 kg). All packaging can be recycled. The waste keys for packaging are: (corrugated board - 15 01 01, wood (pallets) - 15 01 03 and plastic film - 15 10 02)



5 Condition of use

Contents Contents in condition of use: VMZINC® is an alloy made from refined zinc, copper, titanium and aluminium. The ingredients are the base materials listed in point 1. The VMZINC® colour tone is caused by the protective layer which naturally occurs in the atmosphere (patina). This protective layer ensures absolutely maintenance free titanium zinc surfaces and is responsible for the titanium zinc's high resistance to corrosion. In the first stage zinc oxide is formed on the zinc surface. Zinc hydroxide then forms under the influence of moisture (rain). Under the influence of CO2

With the factory made pre-weathered surface qualities QUARTZ-ZINC® and ANTHRA-ZINC® the natural protective layer is formed as described above in outdoor weather conditions. (See Section 9.1 Runoff Rates).

from the atmosphere basic zinc carbonate is then formed, which is then the dense, adhesive and water-insoluble protective layer. The initially bright silvery outside of the titanium zinc changes into a matt, grey-blue patina thanks to this protective layer. This very dense and if injured, "self-healing" layer gives lifetime protection and keeps natural wear very low.

Interrelations Environment - Health

General health and environmental aspects: The EU risk assessment for zinc and zinc compounds began in 1995. Zinc and five zinc compounds were assessed in terms of human health and the environment with the Netherlands as the reporting country. The risk assessment for human life was finished in 2004 and the final draft for the risk assessment report was presented in 2006. The most important conclusions of the risk assessment are:

• There are no health risks for users of zinc products or for people who produce or process zinc or zinc products.

• There are no restrictions on the use of zinc and zinc products. The risk assessment comes to the conclusion that there are no particular risks for the atmosphere, agricultural land or land adjoining the edges of roads. However it did identify some bodies of water in the EU which indicate a higher zinc value. Therefore the measures to reduce risks are based on the implementation of EU regulations already in existence like for example the guidelines on the Integrated Pollution Prevention and Control of the Environment (IPPC) and the EU Water Framework Directive (WRRL), which recognise that increased zinc values in water are mainly linked to specific local sources from industrial sites, historic pollution and local geology. The measures do not include any restrictions on the use of zinc in certain products - this reflects the conclusion of the risk assessment report which states: "The findings of this report reveal that the current use of zinc and zinc compounds does not necessarily lead to the increased regional value which was measured in bodies and deposits of water." Corrosion and runoff rates of VMZINC®

The life cycle of rolled zinc is between 50 and 100 years and depends largely on the CO

products caused by effluent precipitation water:

2 content of the ambient air (the higher the CO2

As CO

content in the air - for example in an industrial area, the lower the life cycle of the rolled zinc).

2

There is a direct correlation between the CO

emissions have significantly dropped in the last 50 years, the life cycle of rolled zinc today is about 100 years even in urban areas and areas which are slightly industrial.

2 content in the ambient air and the rolled zinc's speed of corrosion. Along with this corresponding declines in the zinc ion



content of precipitation water have also been recorded. This has been documented by I. Odnevall Wallinger in various publications. Discharge into flowing waters: We are not aware of exceeding any general quality requirements of flowing water by discharging precipitation water into flowing waters. Ground seepage: Due to seepage there can be locally restricted slightly increased zinc concentrations in the ground/ in technical infiltration, like troughs, rigolen systems and absorbing wells. There is no risk of an excess supply of zinc for the soil/plants/animals.

Reliability of condition of use

VMZINC®

The wear rate of bright-rolled zinc is 2.3 g/m

is UV resistant and rot-free, resistant against rust film and most chemicals used on construction sites.

2

The wear rate of pre-weathered zinc is less than 70% of the wear rate of bright-rolled zinc ("Environmental effect of zinc runoff from phosphated zinc sheet used for building applications“, P.Verbiest u.a., 1999). This results in an accordingly long service life for titanium zinc roofing.

/year ("Comparative LCA of zinc, PVC and aluminium gutter and downpipe systems", TNO Draft Report, October 2007)

6 Extraordinary effects

Fire Fire performance:: The VMZINC®

Development of smoke gas / Smoke density:

products meet the requirements of building material class A1 "non flammable" in accordance with DIN 4102, Section 1.

Formation of zinc oxide smoke with heating above 650°C. Fire gas toxicity: The inhalation of zinc oxide smoke can cause zinc fever (dry throat, cough or aching muscles), which disappears 1 to 2 days after the discontinuation of omissions. Changing the aggregate condition (burning dripping/falling material): The smelting point is 419.5°C.

Water The effect of floods on zinc coils and sheets does not lead to product change or any other negative consequences for the environment.

7 Re-use phase

Re-use / recycling

Zinc coils and sheets cannot generally be directly reused or recycled as a result of the applications specific to the building. However the recycling of zinc from building applications is well established (see below).

Re-use / recycling

Process and new scrap from the manufacturing and processing of VMZINC®

VMZINC® products can be separated by type without any problems with a building's conversion or end of usage phase.

products are fed back completely into the production process. The waste and old scrap from conversion and renovation work on building sites is collected and sold either directly to secondary smelting works or via a scrap metal dealer.

At the end of their life cycle in building applications, zinc products prove to be well worth recycling as a result of their residual value (60 to 75% of the zinc content is remunerated in value). In Western Europe the recycling rate for zinc from construction applications is at least 95%. The share of recycled material in the basic material is about 17% today for the manufacturing of rolled zinc.



The use of recycled material instead of zinc ore has a positive influence on energy use (significant energy savings from 50 to 90%).

Disposal Disposal/Landfilling: As a result of highly developed recycling systems no zinc from roofing, facade cladding, roof drainage sectors are applicable for disposal/landfill. The waste key for zinc is: 17 04 04.

8 Life Cycle Assessment

8.1 Manufacturing of QUARTZ-ZINC® / ANTHRA-ZINC

Declared unit

®

This declaration refers to the manufacturing and recycling of a kilogramme of zinc product under the trademark QUARTZ-ZINC® / ANTHRA-ZINC®

System limits

.

The Life Cycle Assessment for the manufacturing of this product includes the life cycle issues from the "cradle to the grave". Manufacturing includes: • the manufacturing of other raw materials (Ti, Cu, Zn etc.) • transportation of raw materials to production sites • manufacturing of the product (electricity, thermal energy, auxiliaries) • packaging and EoL of packaging (including credits for electricity and thermal energy) • waste water treatment • end-of-life leftovers (commercial waste) The system limits for end of life refer to the life cycle issue of recycling, i.e. the material processing of scrap zinc.

Assumptions and estimates

The data acquisition from plant 1 (Viviez) forms the data basis. Allocations in the manufacturing upstream of "special high grade zinc" are based on conservative assumptions for energy and power supply. (e.g. with ore preparation and zinc extraction). Production scrap is recycled internally (closed loop recycling).

Cutting criteria All of the data from the operating data survey was taken into consideration, i.e. all basic materials used according to the formulation, the thermal energy used, the internal fuel and power consumption, all direct production waste and all emission measurements available in the analysis. Transport expense assumptions were made for all in and outputs taken into consideration. Material and energy flows with a share less than 1 percent were also taken into consideration. It can be assumed that the sum of ignored processes may not exceed 5% of the impact categories. Machinery and systems required for manufacturing are ignored.

Transport All transport of raw materials and auxiliaries are considered regarding the manufacturing of the product.

Period under consideration

The data basis of the life cycle assessment is based on data acquisitions from the company VMZINC from 2008.

Background data The "GaBi 4" software system on comprehensive analysis developed by PE International GmbH is used for modelling the life cycle for the manufacturing and recycling of QUARTZ-ZINC® / ANTHRA-ZINC®. All relevant background data records for the manufacturing of zinc are taken from the GaBi 4 software database, specific data records for the production of QUARTZ-ZINC® / ANTHRA-ZINC® were analysed according to VMZINC details.



Data quality Data used is less than seven years old.

Allocation The recycling potential was calculated according to the requirements of the "Metals for Buildings 2009-09” PCR document. It describes the ecological value of the "enhancement" of a material in the "technosphere". It shows how much environmental impact can be saved in relation to the reproduction of the material (here the avoidance of primary refined zinc production). A collective quota of 96% is assumed for this. Scrap zinc is melted down (remelting quota 94%). After deducting the scrap need in production (closed loop) there is a credit with the "special high grade zinc" data record. As with the recycling potential it is a matter of a saving in manufacturing, it consists of a complete data record with several parameters. If the whole recycling potential is used, the values for manufacturing are reduced by the values for the recycling potential. This represents the life cycle view and is presented in the "Total Manufacturing and Recycling" table of results. Leftovers and packaging materials are burnt in the waste incineration plant. There is a credit with equivalent processes (FR: Power grid mix, FR: Thermal energy).

Information on the usage phase

The usage phase is ignored.

Choice of end of life scenario

In addition to manufacturing the collection and treatment of titanium zinc sheets are modelled. A collection quota of 96% was assumed. The amount of scrap zinc which is available for end of life recycling, after deducting the scrap required for manufacturing, is remelted, the extracted amount of zinc receives a credit.

Credits The credit for the zinc obtained from remelting is calculated based on the data record of primary zinc manufacturing.

8.2 Depicting the analyses and evaluations

Life cycle inventory analysis

Table 2 shows the energy consumption for the manufacturing of 1 kg of QUARTZ- ZINC® / ANTHRA-ZINC®

The consumption of non-regenerative energy for manufacturing is 51.4 MJ from 1 kg of the product.

.

Approx. 87% of this results from the raw materials from the smelting process, 7% of this results from the "rolling" process and 4% from the "pre-weathering" process. Transport and packaging marginally influence primary energy consumption. In addition 8.3 MJ of regenerative energy is consumed for the manufacturing of 1 kg of zinc product. To summarise, the primary energy consumption for the considered product results largely from the smelting process (82% - raw material zinc) and power. The detailed analysis (Figure 1) of the used energy sources shows that Uranium has the largest share of non-regenerative energy sources. The detailed analysis (Figure 1) of the used energy sources shows that hydropower has the largest share of regenerative energy sources. The following table also shows the primary energy of the recycling potential as well as the primary energy consumption for manufacturing.



Table 2: Primary energy consumption of the life cycle of 1 kg of QUARTZ-ZINC®

/ ANTHRA-ZINC

QUARTZ-ZINC

®

® / ANTHRA-ZINC

Analysis factor

®

Unit per kg Total

Manufacturing and Recycling

Manufacturing

Recycling potential

Non-regenerative primary energy [MJ] 15,65 51,39 -35,74

Regenerative primary energy

[MJ] 1,52 8,25 -6,73

4%

24%

10%

13%

49%

QUARTZ-ZINC®/ANTHRA-- ZINC®Distribution of non-regenerative energy carriers

(15,7 MJ gesamt)

Brown coal

Natural gas

Petroleum oil

Anthracite coal

Uranium

0%

66%

30%

4%

QUARTZ-ZINC®/ANTHRA- -ZINC®Distribution of regenerative energy carriers

(1,52 MJ gesamt)

Geothermal heat

Hydro power

Solar power

Wind power

Figure 1: Distribution of consumption of non-regenerative and regenerative primary energy per kg QUARTZ-ZINC

® / ANTHRA-ZINC

If you consider the manufacturing and end of life (melting down of scrap zinc with credit from primary zinc), then it can be established that the recycling potential for primary zinc with 35 MJ primary energy per kg titanium zinc sheet is considerable. This reduces the net primary energy expenditure (life cycle assessment) by almost two thirds.

®

8,25

-6,73

51,39

-35,74

-40 -20 0 20 40 60

Manufacturing

Recycling potential

Non-renewable primary energy Renewable primary energy

Primary energy need (MJ/kg)

Figure 2: Assessment for primary energy consumption per kg QUARTZ-ZINC® / ANTHRA-ZINC®



Waste

The assessment of waste production with the manufacturing of one kg of QUARTZ- ZINC® / ANTHRA-ZINC®

Table 3

is divided into three fractions, excavated/mining waste (including ore processing residue), industrial waste similar to domestic waste and special waste ( ).

The excavated/mining waste represents the largest fraction. This can be predominantly traced back to the extraction of raw materials.

During the production phase the most important influential factor is in the zinc raw material's industrial waste similar to domestic waste category.

Special waste is basically waste from upstream stages, mainly elutriation from the manufacturing of the zinc concentrate as well as the upstream chains for the generation of power. Radioactive waste is caused exclusively by the consumption of power (nuclear power).

Table 3: Production of waste with the manufacturing and incineration per kg of QUARTZ-ZINC® / ANTHRA-ZINC®


Analysis factor

®

Unit per kg Total


Manufacturing

Recycling potential

Mining waste / excavated waste

[kg] 6,12 50,80 -44,68

Industrial waste similar to domestic waste

[kg] 1,14E-02 4,79E-03 6,65E-03

Special waste [kg] 2,54E-02 5,75E-02 -3,21E-02

Impact assessment

The following table depicts the contributions by manufacturing and processing QUARTZ-ZINC® / ANTHRA-ZINC®

Table 4: Estimated impact results for manufacturing and end of life

on the Greenhouse Warming Potential (GWP 100), Ozone Depletion Potential (ODP), Acidification Potential (AP), Eutrophication Potential (EP) and Photochemical Ozone Creation Potential (summer smog potential POCP) impact categories.


Analysis factor

®

Unit per kg Total


Manufacturing

Recycling potential

Greenhouse warming potential [kg CO2 0,70 -equiv.] 3,41 -2,71

Ozone depletion potential [kg R11 equiv.] 2,06E-07 4,73E-07 -2,67E-07

Acidification potential [kg SO2 4,69E-02 -equiv.] 6,78E-02 -2,09E-02

Eutrophication potential

[kg PO4 8,30E-03 -equiv.] 1,05E-02 -2,21E-03

Summer smog potential

[kg ethene equiv.]

1,98E-03 3,09E-03 -1,10E-03

The greenhouse warming potential is dominated by carbon dioxide and VOC. The saving of CO2 emissions in the end of life phase is in contrast to the CO2 emissions



from manufacturing plus CO2 emissions from melting down. The total results in a greenhouse warming potential of 0.70 kg CO2

Power consumption during the manufacturing of "special high grade zinc" has the greatest share of ozone depletion potential in manufacturing.

equiv. for the whole life cycle of 1 kg of the product.

The manufacturing of the zinc raw material and the generation of power contribute to the acid potential and eutrophication potential. The summer smog potential, like the other impact categories, is dominated by the manufacturing of refined zinc. Just like with the acid and eutrophication environmental categories the generation of power is the process with the greatest influence. Only very low impact potentials are left at the end of the life cycle as a result of melting down the scrap zinc and thus preventing the production of primary zinc. Negative values in all considered impact categories result from the recycling potential's credits. Transport and packaging are generally of low significance

9 Requisite evidence

9.1 Runoff rates Trial setup: Duration 1 year (June 1998 to June 1999), in Stockholm, Sweden, titanium zinc sheet 0.7 mm thick in surface qualities VMZINC® bright-rolled and pre-weathered QUARTZ-ZINC® und ANTHRA-ZINC®

inclination of roof = 45°, roof surface direction south facing. ,

Measuring agency: Royal Institute of Technology, Department of Materials Science and Engineering, Division of Corrosion Science – Stockholm in Sweden Report of results: “Atmospheric corrosion of zinc-based materials: runoff rates, chemical speciation and ecotoxicity effects” – I.Odenevall Wallinder, C.Leygraf, C.Karlen, D.Heijerick and C.R.Janssen – Corrosion Science n°43 – pp 809-816 - 2001 Result: As part of this study annual runoff rates were taken from bright-rolled VMZINC® and pre-weathered QUARTZ-ZINC® and ANTHRA-ZINC®

The average annual SO

(other zinc-based construction materials were part of this study).

2 concentration at the measuring agency was 3 µg/m3

The wear rates of bright-rolled VMZINC

, the total amount of precipitation during the experiment was 540 mm.

®

ANTHRA-ZINC

are as follows: ® 1.3 g/m2/year (pre-weathered)

QUARTZ-ZINC® 0.8 g/m2/year (pre-weathered)

In conjunction with other European studies, like for example the risk assessment of zinc and 5 zinc compounds, it was established that the wear rates of bright-rolled zinc had decreased to 2.3 g/m2/year, caused by the reduction of SO2

concentration in the air.



10 PCR document and examination

This declaration is based on the “Metals for Buildings 2009-09” PCR document.

Review of the PCR document by the Expert Committee. Chairman of the Expert Committee: Prof. Dr.-Ing. Hans-Wolf Reinhardt (University of Stuttgart, IWB)

Independent examination of the declaration in accordance with ISO 14025:

internal external

Validation of the declaration: Dr. Frank Werner

11 Literature

GaBi 4 GaBi 4:Software and data base for comprehensive analysis. IKP, University of Stuttgart and PE INTERNATIONAL GmbH, 2001-2005.

IBU 2006 Environmental Product Declaration Guidelines (version dated 20.01.2006) for formulating the product group-specific requirements of Environmental Product Declarations (Type III) for Building Products, Institut Bauen und Umwelt e.V.,

BBS 1997

www.bau-umwelt.com

Bundesverband Baustoffe, Steine und Erden (pub.): Leitfaden zur Erstellung von Sachbilanzen in Betrieben der Steine-Erden-Industrie (Guidelines on drawing up life cycle inventory analyses in plants in the stone and earth industry), Frankfurt, 1997

Eyerer and Reinhardt 2000

Eyerer P., Reinhardt, H.-W. (pub.): Ökologische Bilanzierung von Baustoffen und Gebäuden – Wege zu einer ganzheitlichen Bilanzierung (Ecological analysis of building materials and buildings), Birkhäuser Verlag, Basle 2000

BBS 1999 Bundesverband Baustoffe, Steine und Erden (pub.): Wirkungsabschätzung und Auswertung in der Steine-Erden-Industrie (Impact estimate and evaluation in the stone and earth industry), Frankfurt, 1999

BMVBW 2001 German Ministry of Transport, Building and Urban Affairs (pub.): Leitfaden Nachhaltiges Bauen (Guidelines for sustainable building), Berlin, 2001

Standards and legislation

DIN EN ISO 9001 DIN EN ISO 9001:2008-12, Quality Management Systems - Requirements (ISO 9001:2008); Tri-lingual version EN ISO 9001:2008

DIN EN ISO 14001 DIN EN ISO 14001 2009-11, Environmental Management Systems - Requirements and Instructions for Application (ISO 14001:2004 + Cor. 1:2009); German and English version EN ISO 14001:2004 + AC:2009

http://www.mybeuth.de/langanzeige/DIN+EN+ISO+9001/de/110767367.html&limitationtype=&searchaccesskey=SALL�

http://www.mybeuth.de/langanzeige/DIN+EN+ISO+9001/de/110767367.html&limitationtype=&searchaccesskey=SALL�



DIN ISO 14025 DIN ISO 14025: 2007-10, Environmental Designations and Declarations – Type III Environmental Declarations – Basic Principles and Processes (ISO 14025:2006); German and English versions

DIN EN ISO 14040 DIN EN ISO 14040:2006-10, Environment Management – Ecological Analysis – Basic Principles and Framework Conditions (ISO 14040:2006); German and English versions EN ISO 14040:2006

DIN EN ISO 14044 DIN EN ISO 14044:2006-10, Environment Management – Ecological Analysis – Requirements and Instructions (ISO 14044:2006); German and English versions EN ISO 14044:2006

DIN EN 13501-1 DIN EN 13501-1:2007-05, Classification of Building Products and Methods by Fire Performance – Part 1: Classification with the results of tests on fire performance by building products; German version EN 13501-1:2007

DIN 4102-1 DIN 4102-1:1998-05, Fire performance of building materials and components - Part 1: Building Materials, Terms, Requirements and Tests

DIN EN 506 DIN EN 506:2009-07, Roofing Products made from Metal Sheet - Specifications for Self-Supporting Roofing Elements made from Copper and Zinc Sheets; German Version EN 506:2008

DIN EN 1179 DIN EN 1179:2003-09, Zinc and Zinc Alloys - Primary Zinc, German Version EN 1179:2003

DIN EN 988 DIN EN 988:1996-08 , Zinc and Zinc Alloys - Requirements of Rolled Flat Products for Use in Construction; German Version EN 988:1996

DIN EN 13501-1 DIN EN 13501-1:2007-05, Classification of Building Products and Methods by Fire Performance – Part 1: Classification with the results of tests on fire performance by building products; German version EN 13501-1:2007

DIN 4102-1 DIN 4102-1:1998-05, Fire performance of building materials and components - Part 1: Building Materials, Terms, Requirements and Tests

DIN EN 612 DIN EN 612: 2005-04, Suspended Gutters with Front Guttering Reinforcement and Rain Pipes made from Metal Sheets with Seam Joints; German Version EN 612:2005

VDI 2243 VDI 2243: 2002-07, Recycling-oriented Product Development

http://www.beuth.de/langanzeige/VDI+2243/de/52446692.html&limitationtype=&searchaccesskey=SALL�

Publisher: Institute Construction and Environment e.V. (IBU) Rheinufer 108 53639 Königswinter Tel.: 02223 296679-0 Fax: 02223 296679-1 Email: [email protected]

Layout: PE INTERNATIONAL GmbH Photo credits: Umicore Bausysteme GmbH In the case of a doubt, original EPD “EPD-UMC-2010211-D” shall apply.

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