Vitreous China Ceramic Sanitaryware - EPD

ENVIRONMENTAL PRODUCT DECLARATION
as per ISO 14025
Owner of the Declaration
Programme holder
Publisher
Declaration number
Issue date
Valid to
Kaleseramik Çanakkale Kalebodur Ceramic Industries Inc.
Institut Bauen und Umwelt e.V. (IBU)
Institut Bauen und Umwelt e.V. (IBU)
EPD-KSK-20120016-CBC1-EN
18/08/2012
17/08/2017
Vitreous China Ceramic Sanitaryware
Kaleseramik
www.bau-umwelt.com
Umwelt Produktdeklaration Name des Herstellers – Name des Produkts
General Information
Kaleseramik
Vitreous China Ceramic
Sanitaryware
Programme holder
IBU - Institut Bauen und Umwelt e.V.
Rheinufer 108
D-53639 Königswinter
Owner of the Declaration
Kaleseramik Çanakkale Kalebodur Ceramic Industries
Inc.
Büyükdere Caddesi Kaleseramik Binasi 1
34330 Levent, Istanbul
Declaration number
EPD-KSK-20120016-CBC1-EN
Declared product / Declared unit
Vitreous China Ceramic Sanitaryware / 1 tonne
This Declaration is based on the Product
Category Rules:
Sanitary ceramics, 07-2012
(PCR tested and approved by the independent expert
committee)
Scope:
Issue date
18/08/2012
Valid to
17/08/2017
This declaration is relevant to vitreous china ceramic
sanitaryware produced at a single location at
Çan/Semedeli plant in Çanakkale in Turkey. This EPD
declaration applies to all vitreous china ceramic
sanitaryware production by Kaleseramik. This is an
average EPD which represents the life cycle analysis
of the vitreous china product group. The owner of the
declaration shall be liable for the underlying information
and evidence.
Verification
Prof. Dr.-Ing. Horst J. Bossenmayer
(President of Institut Bauen und Umwelt e.V.)
Prof. Dr.-Ing. Hans-Wolf Reinhardt
(Chairman of SVA)
The CEN Norm EN 15804 serves as the core PCR
Independent verification of the declaration and data
according to ISO 14025
internally
x externally
Dr. Olivier Muller
(Independent tester appointed by SVA)
Product
Product description
Sanitaryware is the generic term used to describe
items which traditionally were made from pottery. i.e.
WC's, Washbasins and Bidets installed within a
bathroom or washroom. Vitreous China is a common
material used for bathroom sanitary ware, such as
console sinks and toilets. Vitreous China sanitaryware
products are primarily made of clay, kaolin, feldspar
and quartz but they may also include small quantities
of other raw materials. Its high gloss, stain resistant
surface is ideal for use in both bathrooms and
kitchens.
The casting slip is made of the above craw materials
are prepared and cast into plaster moulds to form a
green body. The green body then undergoes a natural
drying process and were given a smooth finish.
Glazing is applied before firing at 1200°C to obtain
Vitreous China sanitaryware with almost no water
absorption.
A standard product classification in sanitaryware is as
follows:

Main pieces: toilet pans, basin, lavatory;

Larger bathroom pieces: shower tray,
bathtub;
2

Other pieces: bidet, pedestals, washbasins
and WCs for communities and for disabled
people, etc.
Toilet pans manufactured by Kaleseramik has very low
of water consumption of 2.7lt per flush.
Application
Sanitaryware can be applied in newly constructed
buildings and in renovation and maintenance projects
in both residential and non-residential buildings.
Residential buildings can be rental or privately-owned
houses; non-residential buildings are other buildings
such as commercial offices, but also hospitals and
hotels. The material employed for the realization of the
sanitary products in ceramics (vitreous china, fire clay,
fine fire clay) determines the characteristics and the
final destination of the product.Ceramic sanitaryware is
extremely robust and naturally resistant.
Technical Data
Kaleseramik’s Vitreous China ceramic sanitarywares
are manufactured under the warranty of the ISO
9001:2000 Quality Management System. The
company also has OHSAS 18001 Occupational Health
Environmental Product Declaration Kaleseramik – Vitreous China Ceramic Sanitaryware
and Safety and ISO 14001 Environmental
Management systems in place.
The vitreous china sanitarywares conform to following
standards and specifications:
- The dimensioning of the vitreous china saniatry ware
is shown below (width x length x height mm):
Wash basin:350x345x165 and 650x440x177
WC Pan: 360x510x390, 350x625x420
Cistern: 345x185x355, 352x140x430
Urinal: 310x475x320, 360x550x340
- The ratio of Vitreous China and Fine Fire Clay
products is 97% and 3%, respectively.
Constructional data
Name
Harkord-Cracking Test according
to TL 20
Water absorption test according to
EN 997 (max 0.5%)
Resistance to chemicals and
staining according to NFD 14508:1985
Surface hardness test as per TS
605
Value
Unit
Compliant
-
Compliant
-
Compliant
-
Compliant
-
Resistance to acids according to
NFD 14-508:2012
Resistance to hot alkalines
according to NFD 14-507:2012
Compliant
-
Compliant
-
Base materials / Ancillary materials
Vitreous China ceramic sanitaryware is primarily made
of raw materials such as clay, feldspar, kaolin and
quartz, which are all naturally occurring materials.
Products do not contain any substances that can be
included in “Candidate List of Substances of Very High
Concern for Authorisation” and raw materials used are
not part of the EU REACH regulation.
Ceramic sanitaryware products have a long life and
can be disposed of in inert landfill sites at the end of
their useful life.
Reference service life
This EPD is relevant to cradle to factory gate and
therefore no reference to useful life is required.
LCA: Calculation rules
Declared Unit
The declared unit is 1 tonne of Vitreous China ceramic
sanitaryware products with weights ranging from 8 to
29kg averaging at 15kg.
Declared unit
Name
Value
Unit
Declared unit
Mass per pce. (average)
Conversion factor to 1 kg
1
15
0.001
t
kg
-
System boundary
This is a cradle to gate EPD with options. The system
boundary involves raw materials (A1), transport (A2),
manufacturing (A3) and disposal (C4). ‘Raw materials’
includes pre-treatment before production such as
casting slip, plaster mould and glaze preparations.
Manufacturing stages start with slip casting (forming),
drying, glazing, firing, quality control and packaging.
Transport is only relevant for delivery of raw materials
to the plant and forklift usage within the factory.
Sanitaryware production waste is inert waste, which is
stored on site then disposed of in landfills according to
current legislation.
Packaging is assumed to end up at packaging
recycling streams and plaster mould and product
discards ends up at C&D related waste. The flow of the
process is depicted on the right.
Comparability
Basically, a comparison or an evaluation of EPD data
is only possible if all the data sets to be compared
were created according to EN 15804 and the building
context, respectively the product-specific
characteristics of performance, are taken into account.
This EPD is comparable with fine fire clay ceramic
sanitaryware that comply with the PCR document Part
B: Sanitary ceramics and evaluated according to prEN
15804.
The flow of the process is depicted below:
LCA: Scenarios and additional technical information
Reuse- Recovery- and Recycling potential (D)
Ceramic sanitaryware normally ends up in inert landfill
sites with other building waste. They can be recycled
back for utilization in different applications. They are
often ground into base rock for use in road
construction. In this study, sanitaryware was assumed
to end up in the inert landfill sites along with other
commercial and demolition waste.
3
No possible benefits of recycling and re-use were
taken into account in the LCA work here. Kaleseramik
is looking for an outlet to get this material recycled.
Environmental Product Declaration Kaleseramik – Vitreous China Ceramic Sanitaryware
LCA: Results
DESCRIPTION OF THE SYSTEM BOUNDARY (X = INCLUDED IN LCA; MND = MODULE NOT DECLARED)
BENEFITS AND
LOADS
BEYOND THE
SYSTEM
BOUNDARYS
Use
Maintenance
Repair
Replacement1)
Refurbishment1)
Operational energy
use
Operational water
use
De-construction
demolition
Transport
A3
A4
A5
B1
B2
B3
B4
B5
B6
B7
C1
C2
X
X
X
ReuseRecoveryRecyclingpotential
Constructioninstallation process
A2
Disposal
Transport
A1
Waste processing
Manufacturing
END OF LIFE STAGE
Transport
USE STAGE
Raw material
supply
PRODUCT STAGE
CONSTRUCTI
ON PROCESS
STAGE
C3
C4
D
X
MND
MND MND MND MND MND MND MND MND MND MND MND MND
RESULTS OF THE LCA - ENVIRONMENTAL IMPACT: 1 tonne of Vitreous China Ceramic Sanitaryware
Parameter
Unit
Global warming potential
[kg CO2-Äq.]
Depletion potential of the stratospheric ozone layer
[kg CFC11-Äq.]
Acidification potential of land and water
[kg SO2-Äq.]
Eutrophication potential
[kg PO43-- Äq.]
Formation potential of tropospheric ozone photochemical
[kg Ethen Äq.]
oxidants
Abiotic depletion potential for non fossil resources
[kg Sb Äq.]
Abiotic depletion potential for fossil resources
[MJ]
A1
A2
A3
C4
183.00
1.89E-5
8.28E-2
6.09E-1
41.30
5.87E-6
5.04E-3
1.53E-1
1344.00
1.44E-4
6.93E-1
1.94E+0
16.00
4.22E-6
3.62E-2
9.08E-2
3.52E-1
4.49E-2
9.23E-1
2.33E-2
1.40E+0
3072.00
3.09E-1
703.00
1.14E+1
23068.00
1.93E-1
444.00
RESULTS OF THE LCA - RESOURCE USE: 1 tonne of Vitreous China Ceramic Sanitaryware
Parameter
Unit
A1
A2
A3
C4
Renewable primary energy as energy carrier
Renewable primary energy resources as material utilization
Total use of renewable primary energy resources
Non renewable primary energy as energy carrier
Non renewable primary energy as material utilization
Total use of non renewable primary energy resources
Use of secondary material
Use of renewable secondary fuels
Use of non renewable secondary fuels
Use of net fresh water
[MJ]
[MJ]
[MJ]
[MJ]
[MJ]
[MJ]
[kg]
[MJ]
[MJ]
[m³]
140.00
0.00
140.00
2621.00
0.00
2621.00
IND
IND
IND
9.22
9.98
0.00
9.98
667.00
0.00
667.00
IND
IND
IND
0.36
2204.00
0.00
2204.00
22807.00
0.00
22807.00
IND
IND
IND
9.44
3.30
0.00
3.30
428.00
0.00
428.00
IND
IND
IND
0.47
RESULTS OF THE LCA – OUTPUT FLOWS AND WASTE CATEGORIES:
1 tonne of Vitreous China Ceramic Sanitaryware
4
Parameter
Unit
A1
A2
A3
C4
Hazardous waste disposed
Non hazardous waste disposed
Radioactive waste disposed
Components for re-use
Materials for recycling
Materials for energy recovery
Exported electrical energy
Exported thermal energy
[kg]
[kg]
[kg]
[kg]
[kg]
[kg]
[MJ]
[MJ]
IND
IND
IND
IND
IND
IND
IND
IND
IND
IND
IND
IND
IND
IND
IND
IND
5.82E-2
293.00
IND
IND
IND
IND
IND
IND
IND
1000.00
IND
IND
IND
IND
IND
IND
Environmental Product Declaration Kaleseramik – Vitreous China Ceramic Sanitaryware
References
Institut Bauen und Umwelt 2011
Institut Bauen und Umwelt e.V., Königswinter (pub.):
Generation of Environmental Product Declarations
(EPDs);
General principles
for the EPD range of Institut Bauen und Umwelt e.V.
(IBU), 2011-09
NFD 14 507:2012
Sanitary Appliances - Resistance To Hot Alkaline
Products Of Enamelled Surfaces - Conventional Test
Method
EN 997:2003
WC pans and WC suites with integral trap
www.bau-umwelt.de
PCR 2011, Part A
Institut Bauen und Umwelt e.V., Königswinter (pub.):
Product Category Rules for Construction Products
from the range of Environmental Product Declarations
of Institut Bauen und Umwelt (IBU), Part A: Calculation
Rules for the Life Cycle Assessment and
Requirements on the Background Report. September
2012
www.bau-umwelt.de
ISO 14025
DIN EN ISO 14025:2011-10: Environmental labels and
declarations — Type III environmental declarations —
Principles and procedures
EN 15804
EN 15804:2012-04: Sustainability of construction
works — Environmental Product Declarations — Core
rules for the product category of construction products
NFD 14 506:1985
Sanitary Appliances - Resistance To Domestical
Chemical Agents And Resistance To Stains Of The
Enamelled Surfaces - Conventional Test Method
ISO 9001
DIN EN ISO 9001:2008, Quality Management SystemRequirements
ISO 14001
DIN EN ISO 14001:2004, Environmental Management
Systems-Requirement
OHSAS 18001
DIN EN OHSAS 18001:2007, Occupational Health and
Safety Management System
PCR 2011, Part B
PCR Guidance-Texts for Building-Related Products
and Services, from the range of Environmental Product
Declarations of Institut Bauen und Umwelt (IBU), Part
B: Requirements on the EPD for Sanitary ceramics,
June 2011 www.bau-umwelt.de
Ecoinvent
Ecoinvent Centre www.ecoinvent.org
SimaPro
SimaPro LCA Package, Pré Consultants, the
Netherlands www.pre-sustainability.com
NFD 14 508:2012
Sanitary Appliances - Resistance To Domestical
Chemical Agents And Resistance To Stains Of
Enamelled Surfaces - Conventional Test Method
5
Environmental Product Declaration Kaleseramik – Vitreous China Ceramic Sanitaryware
Publisher
Institut Bauen und Umwelt e.V.
Rheinufer 108
53639 Königswinter
Germany
Tel
Fax
Mail
Web
+49 (0)2223 29 66 79- 0
+49 (0)2223 29 66 79- 0
[email protected]
www.bau-umwelt.com
Programme holder
Institut Bauen und Umwelt e.V.
Rheinufer 108
53639 Königswinter
Germany
Tel
Fax
Mail
Web
+49 (0)2223 29 66 79- 0
+49 (0)2223 29 66 79- 0
[email protected]
www.bau-umwelt.com
Owner of the Declaration
Kaleseramik Çanakkale Kalebodur
Ceramic Industries Inc.
Büyükdere Caddesi Kaleseramik Binasi
1
34330 Levent, Istanbul
Turkey
Tel
Fax
Mail
Web
+90 212 371 52 53
+90 212 269 17 42
[email protected]
www.kale.com.tr
Author of the Life Cycle Assessment
Metsims Sustainability Consulting
Veko Giz Plaza, Meydan Sk. 3
34396 Maslak, Istanbul
Turkey
Tel
Fax
Mail
Web
+90 534 499 32 40
+90 212 705 36 36
[email protected]
www.metsims.com