Brick-Brochure-Green

Boral ®BrickSBuild something great Boral ® bricks are natural products thatare extremely well-suited for constructionprojects planned with the principles ofsustainable design. Boral’s fundamentalobjectives of sustainable design, sometimesdescribed as green building, include:• Reducing the negative effects of building on the environment• Reducing the consumption of non-renewable resources• Minimizing waste• Creating healthy, productive environments• Contributing to the health and comfort of building occupants• Improving building performance overallAccording to the U.S. General Services Administration, sustainable designprinciples include the ability to:• Optimize site potential• Minimize non-renewable energy consumption• Use environmentally preferable products• Protect and conserve water• Enhance indoor environmental quality• Optimize operational and maintenance practices

Boral® Bricks MeetSustainable Design GoalsSelecting natural materials, such as Boral ® brick products,provides environmental advantages for virtually any buildingproject. Brick is composed of mineral elements that standthe test of time without harming the environment as theyage. Brick is an ideal choice for architects and buildersworking to achieve the goals of sustainable design.Brick meets the following standards incorporated in thephilosophy of sustainable design:• Brick does not emit volatile organiccompounds (VOCs) or formaldehyde.• It is a durable, low-maintenance material.• It can be salvaged from existing ordemolished buildings for reuse.• Brick is made using natural resources.• Brick has low “embodied energy”(the energy required to produce andtransport materials).• Brick does not contain CFCs, HCFCsor other ozone-depleting substances.• Brick does not contain highly toxiccompounds, and the production of brickdoes not result in highly toxic byproducts.• Brick creates very little waste when it ismanufactured or recycled.• Brick can be obtained from local resourcesand manufacturers, which means lessenergy is consumed to transport materialsto the job site.• Brick is completely recyclable, either wholefor reuse in new projects or crushed forroadway sub-base or permanent mulch inlandscaping. Brick can also be ground tomanufacture new brick.A Clemson University analysis of the life cycle and sustainabilityof exterior cladding materials suggests that greener buildingscan be achieved by, among other things:• The adoption of load-bearing masonry when possible.• The use of hollow clay brick veneer applications as a means of taking advantageof lower energy consumption in the production and transport of lighter-weight brick.• Designing structures to last beyond a single lifetime, which includes minimizingthe use of wood as a structural element.* Life Cycle Analysis and Sustainability of Modern Building Cladding Materials by Denis A. Brosnan, Ph.D., PE, professor of ceramic and materials engineeringat Clemson University, Clemson, SC, USA © 2001, A. D. Brosnan.

Energy Advantagesof Brick ConstructionAs an exterior cladding material, brick offers energyadvantages on several fronts. Not only is it a green materialcomparatively little energy to manufacture, but building withbrick also results in structures that have greater energyefficiency than structures built with many other exteriorcladding materials, providing long-term energy conservationand savings.From production to recycling, brick provides greater energyadvantages than virtually any other type of exterior cladding:• Brick construction provides the advantagesof thermal mass, holding temperaturesconstant longer than other materials, resultingin more comfortable interior environmentswith greater energy efficiency during bothcold and warm weather.• The insulating air space in brick cavity wallconstruction enhances the advantages ofthe thermal mass properties of brick.• When compared to double-reflectiveglass often used in commercial construction,insulated brick cavity wall constructionresists heat gain approximately 50times better.• When compared to an insulated metalsandwich panel wall commonly used incommercial construction, insulated brickcavity wall construction resists heat gainapproximately nine times better.• The amount of energy needed to producebrick is lower than most building materialsdesigned for comparable use.• Virtually all brick used in constructionnationwide is also manufactured in theUnited States with domestically sourcedmaterials, which results in lower transportationcosts and energy expenditure for theshipment of raw materials.• An abundance of brick manufacturingfacilities located throughout the UnitedStates essentially ensures that less energyis used to transport brick to constructionsites than to transport other materials,such as aluminum or steel.

EnvironmentallyFriendly ManufacturingBeyond compliance, Boral ® embraces the principles ofsustainable development for continued success and growth.To Boral ® , sustainable development in the environmentalsense means:• The non-wasteful use of resources,including energy and water, along withthe development of processes toreduce the amount of energy requiredto manufacture each unit of brick.• Minimizing any adverse impact on theenvironment at extraction and manufacturinglocations and exercising the same level ofcare and responsibility in the rehabilitationand, where required, remediation of sites.Using Natural Materials• Taking into account community needsand expectations, as well as financialconsiderations, in all operations.• Non-renewable resources utilized onthe basis of competent and cost-effectiveextraction, optimal recycling and reuse,and progressive development and reuseof alternative materials and energy.Boral ® brick products are manufactured from two of the most abundant natural materialson the planet – clay and shale.The raw materials that Boral ® uses to produce brick are surface-mined in a way that causes minimallong-term impact to the environment. These are materials that, over the course of centuries, canbe used again and again, or can be broken down without harm and returned to the earth. There iseffectively no waste and the land at extraction locations is reclaimed according to federal and stateguidelines, which often include replanting with trees or lake development.And, unlike other building materials, brick creates little waste when it is manufactured. Mining onepound of clay produces nearly one pound of brick with only slight moisture and mineral loss.Additionally, at some Boral ® facilities, brick is produced with a combination of clay, shale and recycledwood waste materials. The wood waste is burned away during the firing process, which results inlighter-weight brick that can be as much as 20 percent lighter than traditional brick, without sacrificingthe integrity of the brick. Lighter brick has enhanced insulating properties and is also more fuelefficient to transport.Boral’s Terre Haute, Indiana manufacturing facility is the only brick plant in the U.S. to receive a LEEDGold Certification. Additionally, the Salisbury, SC manufacturing facility has been certified as a Cradleto Cradle supplier of natural clay brick products.

Alternative Fuel Sourcesfor ManufacturingRespect is a Boral ® core value, which includes respect for theenvironment and the communities in which Boral ® operates. Aspart of that respect for the environment, Boral ® Bricks is at theforefront of exploring and implementing the use of alternativefuel sources for the manufacturing and firing of brick.methane gasThe U.S. Environmental Protection Agency requires large landfills to capture methaneemissions and either burn them off in a safe, environmentally responsible way or findalternative uses for these emissions. Many scientists believe that methane emissionscontribute to man made global warming. Methane is four times more problematic asa greenhouse gas than when used as fuel.In March 2008, Boral ® Bricks opened its second U.S. facility designed to use methane gas as afuel source for brick manufacturing in Terre Haute, Indiana. Methane is a clean-burning gas that isproduced during the natural decomposition of plants, animal waste and garbage. The Terre Hauteplant is the largest brick manufacturing facility in the country, producing approximately 120 millionbricks per year.The plant location was selected for its proximity to the Victory landfill. Prior to the opening of theBoral ® facility, the methane from the landfill was being flared off to control the methane enteringthe atmosphere. The gas is now tapped and piped to the Boral ® plant for use as an energy sourcein firing and drying brick. In addition to using landfill methane for power, the facility is a zero wasteplant where nearly all materials used are recycled in new batches of brick.The first Boral ® Brick facility to use methane gas in brick production was opened in March 2006,in Union City, Oklahoma. The 165,000-square-foot plant is fueled using a combination of methaneand natural gas.The methane used to fuel the Union City plant is captured from a landfill managed by the OklahomaEnvironmental Management Authority. Boral ® made a substantial investment to develop wells at thelandfill to collect the methane gas. The methane is then piped two miles to the brick manufacturingfacility, where it is used as an energy source for the production of Boral ® bricks. By using methaneas an energy resource, Boral ® has relieved the Union City landfill of the challenging responsibility ofmethane gas disposal.Boral ® is a company committed to cutting-edge, energy-conscience fuel alternatives for manufacturing.By using methane to fuel these plants, an otherwise precarious gas is safely consumed in theproduction of a usable product. The methane produced by these landfills can provide enough fuelto power these brick manufacturing facilities for more than 25 years.wood waste and reclaimed materialsBoral ® uses sawdust-fired kilns at several manufacturing locations and is exploring the use of forestresiduals and reclaimed landfill materials as additional fuel sources. These innovative practices arepart of an ongoing corporate mandate to investigate and develop alternative fuel sources, as well asreduce the energy invested in the production of Boral ® brick products.

Brick andEmbodied EnergyEmbodied energy refers to the energy required to extractraw materials, and manufacture and transport the materialsneeded to build a structure, as well as the energy requiredto assemble and construct the building.There is a large amount of energy embedded in every structure. Because of this, other factors becomeincreasingly important when considering embodied energy, such as the life expectancy of the materials.Since brick can have a life expectancy of 100 years or more, the embodied energy required tomanufacture brick, spread over the life of a building, can be as little as pennies per year. Whencompared based on life expectancy, the energy used to produce brick is lower than most commonlyused building materials, including concrete, glass, steel and aluminum (AIA Environmental ResourceGuide – embodied energy). Because brick is also a natural material that can be reused as well asrecycled in whole or in part, the use of brick in construction provides additional positive contributionsto sustainable design.EMBODIED * ENERGY ANALYSIS OF BRICKMaterial Wood Brick Fiber Cement Concrrete VinylkWh per ton 640 1240 2060 3200 3840Additional energy Requires repeated Other than cleaning, Requires repeated Requires repeated Other than cleaning,requirements painting, staining no maintenance or painting over painting over no maintenance orand/or sealing over additional treatment life of structure* life of structure* additional treatmentlife of structure* is required is requiredProduct life 20–25 years** 100 years 50 years 50 years 50 yearsEmbodied 25.6 kWh 12.4 kWh 41.20 kWh 64.0 kWh 76.8 kWhenergy/lifetime*** per ton per year per ton per year per ton per year per ton per year per ton per year* The manufacturing processes used to produce paint, stain and seal are energy intensive, contributing to the embodiedenergy in the structure calculated over the life of the structure.** Life expectancy depends on quality of maintenance.*** Embodied energy calculated over the life of the structure.

Leed Certification andthe nahb NationalGreen Building StandardThese rating systems, which encompass both commercialand residential construction practices, focus on sustainabledesign principles. These principles consider how the materialsused in construction are manufactured, used and disposedof, including recyclability. The application of materials insustainable design also takes into consideration the energyefficiency and use of resources in the completed building.The LEED TM Green Building Rating System for New Construction and Major Renovations, developedby the U.S. Green Building Council, is a set of performance standards for certifying the design andconstruction of commercial or institutional buildings and high-rise residential buildings of all sizes,both public and private.The intent is to promote healthful, durable, affordable and environmentallysound practices in building, design and construction.Clay brick products that meet or exceed ASTM C216 and/or C652 standards are applicable forboth the LEED and green building rating systems.Here are just a few areas where brick cancontribute to a project being awarded aLEED TM certification.*Note: Points shown below refer to total points allowedin credit, not points contributed solely by brick.CATEGORY: SUSTAINABLE SITESCredit 6 Stormwater Design (1-2 points)Permeable pavements utilizing flexible brick pavementsallow for water to filter back into the ground.Credit 7 Heat Island Effect: Non-Roof (1 point)Light colored brick pavers (plus some select, red pavers)qualify as a hardscape material with an SRI of at least 29.CATEGORY: ENERGY & ATMOSPHERECredit 1 Optimize Energy Performance (1-19 points)Brick is an energy-efficient material with insulating valueand high thermal mass. It can also be used in passive solarconstruction by utilizing its thermal lag to reduce peakenergy loads.CATEGORY: MATERIALS & RESOURCESCredit 1 Building Reuse (1-4 points)Brick has a useful life of more than 100 years. Brick buildingscan often be reused. Brick walls and non-structural elementscan also be reused.Credit 2 Construction Waste Management (1-2 points)Brick’s small unit size helps divert waste from landfillsand salvagedbrick can be used in road construction orother buildings.Credit 3 Materials Reuse (1-2 points)Brick and other masonry are among the most commonlysalvaged building materials.Credit 4 Recycled Content (1-2 points)Numerous manufacturers make brick that incorporatesrecycled or industrial waste aggregates that are renderedharmless when the brick is fired.Credit 5 Regional Materials (1-2 points)The raw materials of brick, clay and shale are abundant andalways nearby,making brick available regionally, efficient totransport and distribute.CATEGORY: INDOOR ENVIRONMENTAL QUALITYCredit 4 Low-Emitting Materials – Flooring Systems (1 point)The use of brick floors avoids carpets and adhesives – leadingto the avoidance of VOCs.CATEGORY: INNOVATION IN DESIGNCredit 1 Innovation in Design (1-5 points)Brick can contribute to superior acoustic comfort. Brickinterior walls do not require paint – leading to the avoidanceof VOCs.Brick structures also can also yield a Life CycleAssessment advantage.CATEGORY: REGIONAL PRIORITYCredit 1 Regional Priority (1-4 points)Brick can help achieve credits that address geographicallyspecificenvironmental priorities.* Categories and Credits apply to LEED (NC) 2009 Rating System.Prerequisites and creditsin the LEED 2009 for NewConstruction and MajorRenovations addresses 7topics and includes specificpoints available as follows:CATEGORYPOINTSSustainable Site 26Water Efficiency 10Energy & Atmosphere 35Materials & Resources 14Indoor Environmental Quality 15Innovation in Design 6Regional Priority 4Total Possible Points 110LEED TM certifications are awardedaccording to the following scale:CATEGORYPOINTSCertified 40-49Silver 50-59Gold 60-79Platinum80 and aboveLEED certification provides an opportunity to demonstrate that environmental goals have been met. For more information about LEED or to register a project for LEED certification,please visit www.usgbc.org. For more information about the NAHB Green Building Program, visit www.nahbgreen.org.

Potential Sustainable DesignContributions from BrickworkENVIRONMENTALLYRESPONSIVE SITESLEED–NC 1 LEED FOR HOMES 2 NAHB NATIONAL GREENBUILDING STANDARD 3REUSE EXISTING BUILDINGSBrick masonry buildings can be renovatedand reused.Materials & Resources (mr)credit 13 pointsSite Design & Development (sd)403.9 6 pointsResource Efficiency (RE)up to 12 pointsurban developmentBrick masonry is suitable and highlyadaptable to urban infill projects.Sustainable Sites (ss)credit 21 pointLocation & Linkage (ll)credit 3.1 or 3.2 1 pointSD401.1 4 pointsLot Design, Preparation &Development (LD)501.1 4 pointslocation on siteSite building to optimize solarradiation (passive solar heatingand cooling possible).SD403.2 6 pointsMaintain open space (brick constructionrequires minimal disruption of site).sscredit 5.21 pointInnovation & Design (ID)credit 1.51 pointstormwater designReduce quantity and improve quality ofrunoff with permeable brick pavement.SScredit 62 pointsSScredit 4.14 pointsSD403.5 5 pointsLD503.4 up to 5 pointsheat island effectLight-colored pavers can helpreduce heat buildup.sscredit 72 pointssscredit 31 pointLD505.2 4 pointsEnergy Efficiency, ThermalComfort and Energy Analysisimproved energy performanceThermal mass of brick helps reduceheat transfer; pressure-equalizedbrick rain screen walls.Energy & Atmosphere (ea)credit 1 up to 10 pointseacredit 1up to 34 pointsEnergy Efficiency (EE)703.1.3 up to 6 pointsEE704.3.1 up to 7 pointsThermal comfortThermal mass of brick helpsreduce indoor temperature swings.eacredit 1up to 10 pointseacredit 1up to 34 pointsEE703.1.3 up to 6 pointsEE704.3.1 up to 7 pointsenergy analysisEnergy modeling reflects benefitsof thermal mass of brick.eacredit 1up to 10 pointseacredit 1up to 34 pointsEE703.1.3 up to 6 pointsEE704.3.1 up to 7 pointsrenewable energyrenewable energyThermal mass of brick walls and floorscan be used in passive solar designs.eacredit 1up to 10 pointsEE3.3.5.1 B 10 points

Potential Sustainable DesignContributions from BrickworkENVIRONMENTALLYPreferable MaterialsLEED–NC 1 LEED FOR HOMES 2 NAHB NATIONAL GREENBUILDING STANDARD 3Life Cycle AssessmentIDcredit 11 pointMRcredit 2.2up to 8 pointsRE609.1 per product: 3 pointsAvoidance ofConstruction WasteUse modular designs to avoid waste.RE601.3 3 pointsRecycling ofConstruction WasteBrick and packaging are 100% recyclable.MRcredit 22 pointsMRcredit 3.23 pointsRE605.1 6 pointsSalvaged materialsSalvaged brick and pavers can be reused.MRcredit 32 pointsMRcredit 2.2 per product: 1/2 pointRE603.2 3 pointsrecycled contentBrick may contain recycled sawdust, sludge,metallic oxides. Mortar/grout may use fly ash.MRcredit 42 pointsMRcredit 2.2 per product: 1/2 pointRE604.1 up to 6 pointsregional materialsBrick manufacturing plants are located nearraw materials and available throughout theUnited States.MRcredit 52 pointsMRcredit 2.2 per product: 1/2 pointRE608.1 per material: 2 pointsmaterials that do notrequire on-site finishesNo finishes are required of brickwork.can be used inside as well.RE601.7 per material: 2 or 5 pointsmaterials made withrenewable energySeveral brick manufacturers use landfillgas or sawdust to fire brick.RE606.3 per material: 2 pointsDURABILITY AND DESIGNFOR SERVICE LIFEDURABILITYBrick has a useful life of more than 100 years.Termite-Resistant Materialsin areas of Termite InfestationInsects do not eat brick.SScredit 5up to 1 pointRE602.8 up to 6 pointsWeather-Resistant Barrieror Drainage Plane Inside Sidingor VeneerBrick veneer introduced the drainage wall.RE2.2.9 8 pointsflashingFlashing is always present in well-detailedbrick buildings.RE602.12 6 pointsacoustic comfortacoustic comfortBrick walls provide an STC of 45 or higher.

Potential Sustainable DesignContributions from BrickworkSAFETY & SECURITYLEED–NC 1 LEED FOR HOMES 2 NAHB NATIONAL GREENBUILDING STANDARD 3fire-resistant constructionBrick will not burn or emit toxic fumes.Impact-Resistant ConstructionBrick masonry resists damage fromwindborne debris and other impacts.efficient use of materialsmaterials withmultiple functionsBrick walls can serve as structure and finish,provide acoustic separation and providethermal mass.RE601.9 4 pointsUse Products that ContainFewer Resources thanTraditional ProductsThinner brick units use less materialand weigh less; hollow brick units useless material and can be reinforced.RE607.1 per material: 3 pointsFoundations thatRequire Less MaterialPier and panel foundations of brickmeet this practice.RE601.8 3 pointsStructural Systemsthat Optimize Material UseEngineering design, rather than empiricaldesign, of brick walls provides betterutilization of materials.RE601.2 3 pointsSUPERIOR INDOOR AIR QUALITYavoid vocsInterior brick walls paint.Indoor Environmental Quality (EQ)credit 4.21 pointMRcredit 2.2 per product: 1/2 pointIE901.8 points dependon applicationInterior brick floors carpetsand adhesives.EQcredit 4.31 pointMRcredit 2.2 per product: 1/2 pointIE901.8 points dependon applicationmoldWith moisture-tolerant materials andfinishes, brick is not a food source formold and can be easily cleaned.miscellaneousProduct manufactureris ISO 14001 certifiedRE610.1 per percent: 1 point1 LEED–NC version 2.2 – Total possible points = 692 LEED for Homes (January 2008) – Total possible points = 1363 NAHB National Green Building Standard, Draft 2 (2008) – Total possible points = approximately 2000

Sourcing fromRegional MaterialsThe Leadership in Energy and Environmental Design(LEED) Green Building Rating System TM offers points inthe certification system in the Materials and Resourcescategory under credit 5 for purchasing materials sourced,recycled or manufactured within a 500-mile radius of theproject site. Using regional materials reduces the use offossil fuels for transporting materials.Graph below shows 500-mile radius around Boral ® brick manufacturing facilities.Boral ® brick manufacturing facility500-mile radius

Build something great Life Cycle Analysis of BrickThe chart below provides an across-the-board comparison of brick to block masonry, EIFS, fi bercement and vinyl siding. The comparisons in the chart are based on the energy used to manufactureand ship each of these products, as well as other environmental factors to consider when choosingexterior cladding. The fi gures are determined based on the total life span or life cycle of the structure;e.g., the total amount of energy required to produce the product averaged over the anticipated life ofthe product. The life cycle is established as the length of warranty for each product.CLADDINg / LIFE CYCLE ANALYSISBaSic data Brick MaSonry Block MaSonry FiBer ceMent Vinyl SidinG eiFSWarranty 100 yearS 50 yearS 50 yearS 50 yearS 5 yearSWeiGht / Ft 2 35.5 lB 42.8 lB 2.3 lB 0.5 lB 1.24 lBenerGy, MininG and recyclinG: recyclinG: recyclinG: recyclinG: recyclinG:ManUFactUrinG Brick 100% 80% 0% 80% 0%Mortar 40%recyclinG and enerGy: enerGy: enerGy: enerGy: enerGy:enerGy kWh / Ft 2 / yr 0.252 0.228 0.328 0.210 5.48PollUtion 0.011 0.005 0.026 0.001 0.023Water and aireMiSSionS lB / Ft 2 / yrdiStriBUtion enerGy 175 MileS 100 MileS 365 MileS 310 MileS 300 MileSaVG / diStance, 0.004 0.004 0.146 0.001 0.189 3MileS and net enerGykWh / Ft 2 / yrWaSte and dePletion 0.108 0.203 0.048 0.460 4 0.828lB / Ft 2 / yrtotalSenerGy 0.256 0.232 0.474 0.211 5.669PollUtion 0.011 0.005 0.026 0.001 0.023WaSte and 0.108 0.203 0.048 0.460 0.828dePletionResearch data in chart was generated by the National Brick Research Center, Clemson University.1 No proven method available.2 Used to maximum allowed in this analysis (80%). According to the Vinyl Siding Institute, 100% ofvinyl is recyclable. Some environmental groups claim recyling of vinyl siding results in dioxin emissions.3 Low weight per truckload influenced results.4 Depletion of salt in processing PVC influenced results.© 2011 Boral Bricks Inc.2703