concrete roof tile

ENVIRONMENTAL PRODUCT DECLARATION of
CONCRETE ROOF TILE
“COPPO MEDITERRANEO WITH GROUT SURFACE”
of
Rev.0 – Date: 2010-09-14
Registration n°: S-P-00140

LIST OF CONTENTS
1. ORGANIZATION AND PRODUCT DESCRIPTION...................................................................................................... 3
1.1 Organization............................................................................................................................................ 3
1.2 Product .................................................................................................................................................... 3
1.3 Content declaration ................................................................................................................................. 4
2. ENVIRONMENTAL PERFORMANCE DECLARATION................................................................................................. 4
2.1 Methodology............................................................................................................................................ 4
2.2 Functional Unit ........................................................................................................................................ 4
2.3 System boundaries ................................................................................................................................. 4
2.4 Data quality ............................................................................................................................................. 6
2.5 Use phase informations .......................................................................................................................... 7
2.6 End of life informations............................................................................................................................ 7
2.7 Impact assessment ................................................................................................................................. 8
2.7.1 Potential environmental impact of manufacturing phase................................................................ 8
2.7.2 Resource use and waste generation of manufacturing phase ....................................................... 8
2.7.3 Potential environmental impact, resource use and waste generation of distribution phase
scenario .................................................................................................................................................... 9
3. INFORMATION ABOUT ORGANIZATION AND CERTIFICATION BODY.......................................................................... 9
3.1 Contacts .................................................................................................................................................. 9
3.2 Other registrations of Organization ......................................................................................................... 9
3.3 Certification body .................................................................................................................................. 10
3.4 Other informations................................................................................................................................. 10
3.5 References............................................................................................................................................ 10
GLOSSARY ........................................................................................................................................................ 11
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1. ORGANIZATION AND PRODUCT DESCRIPTION
1.1 Organization
Gambale started colours concrete roof tiles production in 1969 using only 6 employees and a semi-automatic
plant with a production capacity of 1000 roof tiles per hour. In 1974 we had a technological innovation with
the acquisition of a new totally automatic plant with a production capacity of 2300 roof tiles per hour. Today
the Gambale area is 50000 m 2 with 4 sheds for the complete production of the roof system. The production
capacity is 64000 swages per day for concrete roof tiles.
The Gambale system is certified ISO 9001. The concrete roof tiles have a quality label ISTEDIL (Istituto
Sperimentale per l’Edilizia), the quality label EN 490 and they are under warranty for 30 year.
1.2 Product
Gambale produces 4 types of concrete roof tiles: Coppo Portoghese, Doppia Romana, Doppio Coppo and
Coppo Mediterraneo. The EPD product is Coppo Mediterraneo made in grout surface and 2 different colors:
Antica Toscana and Vecchio Piemonte (fig.1.1). In table 1.1 are described the technical data of concrete roof
tile.
Fig.1.1- The Coppo Mediterraneo “Antica Toscana” and “Vecchio Piemonte”
THECNICAL DATA
Dimension cm. 42 x 33
Width of covering cm. 30
Weight per piece kg 4.8
Weight per m 2 according to
superposition
Amount per m 2 according
to superposition
kg 44.65 ± 49.35
9.5 ± 10.5
Colours with grout surface
Vecchio Piemonte
Antica Toscana
Tab.1.1- The technical data of concrete roof tile
The concrete roof tiles are tested according to UNI EN 490:2005 and UNI EN 491:2005 which guarantee the
water impermeability, resistance to freezing cold, resistance to thaw and ultimate strength.
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1.3 Content declaration
In tab.1.2 are described information about content declaration of material and chemical substance in the
product life cycle.
MATERIAL/ SUBSTANCE CAS-NUMBER ENVIRONMENTAL
CLASS
HEALTH-CLASS
COMPONENTS CEMENTS 65997-15-1 no
R36/37/38 R43
INERTS
no
PERCENTAGE (%) OF MATERIALS
AND SUBSTANCES TOTAL WEIGHT
no 99.53
INORGANIC PIGMENTS 1309-37-1
1317-61-9
no
no
51274-00-1
0.035
ACRYLIC ADDITIVES 111-76-2 no R 20/21/22. R 36/38 0.322
LUBRICANTS AND OILS - 1
- 1
- 1 0.103
64742-47-8 no
R65, R66
PACKAGING no no no 0.01
TOTAL 100
Tab.1.2- Content declaration of concrete roof tile [% for 1 t of tile]
Some materials and substances listed in tab.1.2 contain percentages of dangerous substances, which are in
such concentrations to be at the limit allowed by the Substances and Preparations Directive 2 .
2. ENVIRONMENTAL PERFORMANCE DECLARATION
2.1 Methodology
The methodology used for environmental performance calcultation is the Life Cycle Assessment (LCA),
according to ISO 14040:2006 and ISO 14044:2006. The characterization factors in Appendix A of
Requirements for Environmental Product Declarations, EPD MSR 1999:2, Swedish Environmental
Management Council 2000-03-27, have been used to make the Life Cycle Impact Assessment (LCIA) phase.
2.2 Functional Unit
The functional unit (FU) is 1 tonne (t) of selling (production capacity – scraps production) Coppo
Mediterraneo with grout surface concrete roof tile, produced in 2009 in the Gambale site, Mirabello (Ferrara,
Italy).
2.3 System boundaries
The system boundaries (figure 2.1) consist from the extraction of raw material, the transformation and
transport to final product distribution to customers. The product manufacturing includes the following phases:
the supplying raw materials, materials and additives; the blending to getting the concrete; the press-
1
Data lacking.
2
Council Directive 76/769/EEC of 27 July 1976 on the approximation of the laws, regulations and administrative provisions of the
Member States relating to restrictions on the marketing and use of certain dangerous substances and preparations, and subsequent
amendments. European legislation. In Italy: D.M. 10/05/2004 “Recepimento della Direttiva 2003/53/CE recante la XXVI modifica alla
Direttiva 76/769/CEE del Consiglio del 27 luglio 1976, relativa alle restrizioni in materia di immissione sul mercato e di uso di talune
sostanze e preparati pericolosi”.
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extrusion; the grouting; the resin application; the natural drying; the roof tiles collection (swages removal);
the packing and the stocking; the ordinary maintenance. For the LCA study it has been created a model to
schematize life cycle of concrete roof tile and as follows:
MANUFACTURING PHASE:
- Blend preparation (extraction of raw materials and supplying materials)
- Grout preparation (extraction of raw materials and supplying materials)
- Ancillary materials (supplying additive materials)
- Energy consumptions (aggregate for all manufacturing phases)
- Fuel consumption for handling goods
- Packagings (supplying plastic bands)
- Ordinary maintenance (supplying lubricating materials)
DISTRIBUTION PHASE:
- Product distribution from Gambale plant to costumers.
Since the transport distance doesn’t depends by the manufacturers but by the purchasers location and this
varies during the time, the result in the impact assessment is indicated for the generic distance of 100 km
(section 2.7.3).
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EXTRACTION RAW MATERIALS
AND SUPPLYING MATERIALS
Transport
BLENDING
MANUFACTURING
PAHSE
PRESS-EXSTRUSION
GROUTING
INPUT
RESOURCES
ENERGIES
TRANSPORTS
RESIN APPLICATION
NATURAL DRYING
SWAGES REMOVAL
OUTPUT
WASTES
EMISSIONS TO AIR,
WATER AND SOIL
PACKING AND STOCKING
DISTRIBUTION
USE
PHASE
USE AND END OF LIFE
Not included in the impact assessment
Fig.2.1- The system boundaries of life cycle concrete roof tile
Exclusions
As set out in the PCR 2008:04, the following processes are not included: the construction of factory buildings
and infrastructure; the production of manufacturing equipment; the maintenance and production of spare
parts which have a life cycle longer than three years (e.g. the aluminium swages); the packaging of raw
materials; the personnel activities.
In addition, the following processes are not included: product use by costumers (described in qualitative
terms in paragraph 2.5); product end of life treatments (described in qualitative terms in paragraph 2.6).
2.4 Data quality
The data used for the LCA study are collected in the Gambale production site and site-specific data provided
by Gambale according to 2009. The data of database used for impact assessment are: Ecoinvent 1.2, ETH-
ESU 96, IVAM LCA 3, BUWAL 250 e IDEMAT 2001.
The electricity mix used by Gambale is the Italian one (in LCA study it has been considered the italian mix
electricity of Ecoinvent database).
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For the transports representation (from supplying firms to Gambale and from Gambale to costumers) it has
been used the actual transportation model present in Ecoinvent 1.2, ETH-ESU 96 and IDEMAT 2001
database. The veicule types and the distances are based on real data provided by Gambale and supplying
firms.
According to the Requirements for Environmental Product Declarations (MSR 1999:2), the environmental
impact associated to generic data don’t exceed 10% of the overall environmental impact due to the Gambale
product system (they are ≤ 1%).
2.5 Use phase informations
Generally, the concrete roof tile use phase includes: building site operations and security plans for height
works; the covering scheme; the laying of elements for roof covering impermeability; the covering
maintenance. All these aspects are very significant for the roof durability. The durability is an important
building characteristic because it permits to last long and have the best performances as long as possible.
The durability dependes on: material quality; the techniques layed to installation and weather events to which
roof covering is subject 3 . The Gambale concrete roof tiles are under warranty for 30 years and they have a
durability as building ones (i.e. 80 or 100 years). Gambale provides assistance to operators during roof
covering design, it provides assistance for laying techniques and for technical solutions in order to preserve
the roof covering characteristic in serious weather events (e.g. hail, water seepage and freezing).
2.6 End of life informations
It is considered very important to communicate which can be the concrete roof tile disposal scenarios, within
environmental in force legislation, in order to follow the best available technology (BAT) promoting the end of
life treatments for recovery or recycling material instead of disposal in landfills. In fact, Gambale recovers
all the concrete roof tiles scraps. One of the main characteristics of concrete roof tiles is that they can be
completely reusable, after crushing, as inert in other manufacturing and/or product. This aspect facilitates
the spread of criteria for selective buildings demolition. The selective building demolition method enables
separation of different building components (e.g. the concrete) through techniques aimed at obtaining
homogeneous material fractions reusable again. It is advisable to include in product design phase the
material recovery and recycling scenarios and include in the end of life phase the techniques to separate
materials recovered. The waste of concrete roof tile, according to environmental italian legislation, is
identified as “special waste non-hazardous” and it is a waste that derives from “construction and demolition
waste” (C&D). According to italian annual statistics 4 the “C&D wastes” are recovered for 56.3%.
3
Source: C.Pellanda, “La manutenzione delle coperture”, Il Tetto, informazione, cultura e tecnica edilizia. Marzo 2006, n°84.
4
Source: Rapporto rifiuti 2007 -Estratto- APAT, Agenzia per la Protezione dell’Ambiente e per i servizi Tecnici, Gennaio 2008.
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2.7 Impact assessment
2.7.1 Potential environmental impact of manufacturing phase
Table 2.1 illustrates the potential environmental impact of 1 t (functional unit) of concrete roof tile life cycle in
the manufacturing phase, in terms of the environmental impact categories, according to PCR 2008:04:
Global warming (kg CO 2 eq), Ozone depletion (kg CFC-11 eq.), Photochemical oxidation (kg C 2 H 4 eq),
Eutrophication (kg O 2 ), Acidification (kmol H+ eq.).
POTENTIAL ENVIRONMENTAL IMPACT
IMPACT CATEGORY UNIT TOTAL MANUFACTURING PHASE
GLOBAL WARMING (GWP100) kg CO 2 eq 253
OZONE LAYER DEPLETION (ODP) kg CFC-11 eq 1.3·10 -5
PHOTOCHEMICAL OXIDATION kg C 2 H 4 eq 0.02
EUTROPHICATION kg O 2 3.1
ACIDIFICATION kmol H+ eq 0.02
Tab.2.1- Potential environmental impact of LCA concrete roof tile [FU: 1 t of roof tiles]
2.7.2 Resource use and waste generation of manufacturing phase
Tables 2.2 and 2.3, describe results concerning to resource use (renewable and non-renewable with and
without energy content) and wastes, generated by 1 t of concrete roof tile life cycle in the manufacturing
phase.
RESOURCES USE WITH ENERGY CONTENT [kg]
TOTAL MANUFACTURING PHASE
TOTAL NON RENEWABLE 5 41.5
TOTAL RENEWABLE 6 0.5
ENERGY CONTENT OF RESOURCES USED [MJ]
TOTAL MANUFACTURING PHASE
TOTAL NON RENEWABLE 1575
TOTAL RENEWABLE 7 100
DIRECT ELECTRICITY CONSUMPTION 68.7
RESOURCES USE WITHOUT ENERGY CONTENT [kg]
TOTAL MANUFACTURING PHASE
TOTAL NON RENEWABLE 1161
TOTAL RENEWABLE 8 524699
Tab.2.2- Resources use with energy content [kg for 1 t of roof tiles]; Energy content of resources used [MJ for 1 t of roof
tiles]; Resources use with energy content [kg for 1 t of roof tiles].
WASTES GENERATION [kg]
TOTAL MANUFACTURING PHASE
HAZARDOUS 4·10 -3
OTHERS 33.3
Tab.2.3- Wastes generation [kg for 1 t of roof tiles]
5
Coal, gas, oil, peat, uranium.
6
Wood.
7
Energy from: hydro power, biomass, wind, barrage water, solar.
8
Water.
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2.7.3 Potential environmental impact, resource use and waste generation of distribution phase
scenario
Tables 2.4 and 2.5, describe results concerning to potential environmental impact, resource use (renewable
and non-renewable with and without energy content) and wastes, generated by 1 t of concrete roof tile life
cycle in the distribution phase scenario.
SCENARIO FOR 100 km
POTENTIAL ENVIRONMENTAL IMPACT –DISTRIBUTION PHASE-
IMPACT CATEGORY UNIT TOTAL DISTRIBUTION PHASE
GLOBAL WARMING (GWP100) kg CO 2 eq 21.8
OZONE LAYER DEPLETION (ODP) kg CFC-11 eq 3.2·10 -6
PHOTOCHEMICAL OXIDATION kg C 2H 4 eq 8,4·10 -4
EUTROPHICATION kg O 2 1.2
ACIDIFICATION kmol H+ eq 5·10 -3
Tab.2.4- Potential environmental impact of LCA concrete roof tile distribution phase [FU: 1 t of roof tiles]
SCENARIO FOR 100 km
RESOURCES USE AND WASTES -DISTRIBUTION PHASE-
RESOURCES USE WITH ENERGY CONTENT RESOURCES USE WITHOUT ENERGY CONTENT
WASTES GENERATION
UNIT TOTAL UNIT TOTAL UNIT TOTAL
NON
RENEWABLE kg 8.18
NON
RENEWABLE kg 27.3 HAZARDOUS kg 1·10 -3
RENEWABLE kg 0.03 RENEWABLE kg 30832 OTHERS kg 2.36
Tab.2.5- Resource use renewable and non-renewable with and without energy content, wastes generation, in the
distribution phase scenario for 100 km [kg for 1t of roof tiles]
3. INFORMATION ABOUT ORGANIZATION AND CERTIFICATION BODY
3.1 Contacts
- Gambale Srl.: C.so Italia 538, 44043 Mirabello (FE) – Phone (+39) 0532-849714. Fax. (+39) 0532-
849545. Web-site: http://www.gambaletegole.com. E-mail: info@gambaletegole.com. Referring:
Stefano Gambale.
- LCA technical support: LCA-lab Srl, Spin off ENEA - c/o ENEA (Italian National Agency for New
Technologies, Energy and Sustainable Economic Development), Via Martiri di Montesole 4, Bologna,
Italy – Phone (+39) 051-6098607/518. E-mail: info@lca-lab.com.
3.2 Other registrations of Organization
- Quality management system: ISO 9001:2000 (n°4421), approved by Certiquality.
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- Quality label ISTEDIL (Istituto Sperimentale per l’Edilizia).
- Quality label DIN EN 490:2005-03 approved by Güteschutz Beton (Düsseldorf).
3.3 Certification body
The present EPD and associated Life Cycle Assessment have been approved by the accredited Certification
body Certiquality, in accordance with MSR 1999:2 provided by the Swedish Environmental Management
Council.
Valid up to 17 September 2011.
3.4 Other informations
This EPD is a result of a project started in partnership with the Associazione Produttori Tegole in Cemento
(APTC) (Association of the Manufacturers Cement Roof Tiles) in order to develop the environmental
sustainability among organizations associated and promote the diffusion of Environmental Product
Declaration for concrete roof tile product category.
This EPD and further related information are available in website: www.environdec.com.
The specific PCR for this category of products are PCR 2008:04, Product Category Rules (PCR) for
Concrete roof coverings, concrete roof tiles and concrete complementary of the roof system, Version 1.0
2008-06-16 and these are consultable in website www.environdec.com.
3.5 References
- ISO 14050:2002, Environmental management- Vocabulary.
- P.Neri, G.Olivieri “Analisi del ciclo di vita (LCA) della tegola in calcestruzzo Coppo Mediterraneo con
superficie boiaccata di Gambale Srl ai fini della certificazione EPD. Revisione dati 2010”, LCA-lab SRL,
doc. RT-45_Rev.00, 13/09/10, pp.1-44, Bologna, Italy.
- PCR 2008:04, Product Category Rules (PCR) for preparing an Environmental Product Declaration
(EPD) for Concrete roof coverings, concrete roof tiles and concrete complementary of the roof system,
Version 1.0 2008-06-16, the Swedish Environmental Management Council, available on
www.environdec.com
- Requirements for Environmental Product Declarations, EPD (MSR 1999:2), published by the Swedish
Environmental Management Council.
- Requirements for an International EPD Scheme, LIFE INTEND (LIFE 03 ENV/IT/000324) Version 1.0,
June 2005.
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GLOSSARY
Allocation: Partitioning the input or output flows of a process or other product system to the product system under study
Acidification: Change in an environment's natural chemical balance caused by an increase in the concentration of
acidic elements.
CAS-number: CAS registry numbers are unique numerical identifiers for chemical compounds, polymers, biological
sequences, mixtures and alloys. Chemical Abstracts Service (CAS), a division of the American Chemical Society,
assigns these identifiers to every chemical that has been described in the literature. The intention is to make database
searches more convenient, as chemicals often have many names. Almost all molecule databases today allow searching
by CAS number.
Characterization factor: Factor derived from a characterization model that is applied to convert the assigned LCI results
to the common unit (allows aggregation into category indicator result) of the category indicator.
Data quality: Characteristics of data that bear on their ability to satisfy stated requirements.
Eutrophication: Excessive enrichment of waters with nutrients, and the associated adverse biological effects.
Functional Unit: Quantified performance of a product system for use as a reference unit.
Global warming: Changes in the surface-air temperature, referred to as the global temperature, brought about by the
greenhouse effect which is induced by emission of greenhouse gases into the air.
Input: Material or energy, which enters a unit process.
Impact category: Class representing environmental issues of concern to which LCI results may be assigned.
Life Cycle Assessment (LCA): Compilation and evaluation of the inputs, outputs and the potential environmental
impacts of a product system throughout its life cycle.
Life Cycle Impact Assessment (LCIA): Phase of life cycle assessment aimed at understanding and evaluating the
magnitude and significance of the potential environmental impacts of a product system.
Life Cycle Inventory analysis (LCI): A phase of life cycle assessment involving the compilation and quantification of
inputs and outputs, for a given product system throughout its life cycle.
Life Cycle Inventory results: A list of emissions, resource uses, land use, etc. that are collected, before impact
assessment is applied.
Output: Material (may include raw materials, intermediate products, co-products, products and releases) or energy that
leaves a unit process.
Ozone layer depletion: The fragile shield of ozone is being damaged by chemicals released on earth. The main
chemicals that are depleting stratospheric ozone are chlorofluorocarbons which are used in refrigerators, aerosols, and
as cleaners in many industries, and halons, which are used in fire extinguishers.
Photochemical oxidation: A combination of fog and chemicals that come from automobile and factory emissions and is
acted upon by the action of the sun.
Product Category Rules (PCR): Technical information documents that define the rules to be adopted for the
preparation of LCA and EPD in order to compare specific homogeneous category of products/services.
Process: Set of interrelated or interacting activities that transforms inputs into outputs.
Product: Any goods or service
Product system: Collection of unit processes with elementary and product flows, performing one or more defined
functions, that models the life cycle or a product.
Raw material: primary or secondary material that is used to produce a product
System boundary: A set of criteria specifying which unit processes are part of a product system
Unit process: Smallest element of a product system for which data are collected when performing a life cycle
assessment.
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