How To Make Steel Structures

Transcription

1 ENVIRONMENTAL PRODUCT DECLARATION STRUCTURAL STEEL CONSTRUCTION PRODUCTS ENVIRONMENTAL PRODUCT DECLARATION EN ISO 14025

2 General information Owner of environmental product declaration Product Manufacturer Manufacturing sites Product applications Declared unit Suolakivenkatu 1, FI Helsinki, Finland tel Welded and coated steel structures made of hot-rolled plates, sheets and coils, and cold-formed tubes and sections Ruukki Peräseinäjoki and Ylivieska (Finland), Gargzdai (Lithuania), and Oborniki (Poland) Frames of buildings and structures 1 kg of steel structures Date declaration was issued 31 August 2014 Valid until 31 August 2019 This environmental product declaration contains several different steel structures for buildings and other structures. The results of environmental indicators stated in this declaration are average values for these products. The EPD of construction products may not be comparable if they do not comply with the standard EN and EN ISO The information in the environmental product declaration is based on production data for CEN standard EN serves as the core PCR. Independent verification of the declaration, according to EN ISO 14025:2010 External Third party verifier Internal Thomas Andersson, Insinööritoimisto Ecobio Oy Product Application Steel structures are highly prefabricated, ready-to-install, energy-efficient solutions for single- and multistorey buildings. A frame solution for multi-storey buildings usually consists of workshop-primed WQ beams and coated composite columns, which can be used to create modifiable premises. Typical single-storey buildings are constructed using prefabricated trusses. There are also many fire protection solutions available for frames. Ruukki s building products can impact positively on the overall assessment of buildings for LEED and BREEAM certification. For more information, visit and Technical information This environmental product declaration covers steel structures made by Ruukki in Peräseinäjoki and Ylivieska (Finland), Gargzdai (Lithuania) and in Oborniki (Poland). Choice of production site is determined according to, for example, product requirements and construction site location. Steel made in Raahe steel mill in Finland is used in the structures. Steel structures include steel beams, girders, columns, trusses, bonds and embedded fixtures made in conformity with EN 1090 standard. Welded sections and WQ beams are made from hot-rolled, plate, sheet and coil. Trusses and structural tubes are made of cold-formed tube. 2

3 Coating is chosen according to customer requirements and the corrosivity category. Coating is done using 1 3 layers of either polyurethane, zinc powder, alkyd or epoxy paint. Coating thickness is μm depending on the corrosivity category. If fire-retardant paint is required, it is added between the primer and top coat in frames. Coating thickness of fire-retardant paint depends on fire resistance requirements. Ruukki has the right to use CE-marking for its load-bearing steel structures in accordance with the EN 1090 standard. By affixing CE marking to its products, the manufacturer declares that the product complies with all the relevant regulations and especially with essential health, safety and environmental regulations. Steel density is kg/m 3. The masses and material strengths are specified in the product descriptions at Other technical properties are selected by the customer. Product composition Steel is an alloy of mainly iron and carbon, with small amounts of elements used as alloying elements. These elements improve the chemical and physical properties of steel such as strength, durability and corrosion resistance. The alloying elements of steel are closely linked to its chemical matrix. The steel used in steel structures meets the quality criteria for steel according to EN standards. Welding consumables and coatings are the other raw materials used in the manufacture of steel structures.. Ruukki actively tracks and anticipates future changes in environmental, safety and chemical legislation and complies with valid EU chemical regulations, such as REACH (1907/2006/EC) and CLP (1272/2008/EC). Communication and cooperation throughout the supply chain plays an important role and Ruukki requires full REACH compliance from its subcontractors. Ruukki tracks the list of Substances of Very High Concern (SVHC) and other legislative requirements to ensure products meet legal and customer requirements. In addition, Ruukki observes and complies with the requests and recommendations of many customers to withdraw products containing hazardous substances in the construction sector. Table 1 shows an example of the typical chemical content of steel structures on delivery to the customer (excluding packaging materials). Table 2 shows the average and maximum content (%) of coating of total product weight in steel structures. Product composition varies according to customer requirements, selected materials and coatings. Content information is based on steel produced at Ruukki s steelworks in Finland. Where the concentration % (w/w) in a product of substances restricted under the EU s chemical regulation (REACH) and recommendations phasing out hazardous substances in the building sector such as the requirements of BASTA (2014: A2) and Byggvarubedömningen (Building Material Assessment, BVB, 2013) in Sweden and the priority list in Norway exceeds or corresponds to the limits referred to above, this is stated in Table 1. The guidelines for Swedish building product declarations (Föreningen för Byggvarudeklarationer, BVD 3, 2007) have been taken into account with regard to the substances disclosed. More information about the composition of steels can be found in national and international standards and on Ruukki Construction s website at Values are based on European Standards EN , EN , EN , EN , EN requirements on maximum concentrations. 3

4 Table 1. Example of the composition of a typical steel structure Material Steel > 96* Coating < 3.7* Welding consumables Content (%) of total product weight Name of ingredient Maximum part content, % (w/w) Content % (w/w) of total product weight CAS number Iron (Fe) Manganese (Mn) Silicon (Si) Carbon (C) Risk and hazard phrases and other data on the ingredient Nickel (Ni) 0.5 < R40-43; H351, H317 Cobalt (Co) < R42/43-53; H334, H317, H413 Zinc powder** < R ; H400, H411, H413 Zinc borate*** < 2.5 < , < 0.3 Iron (Fe) 97.5 < Remarks * In fire-protected structures, the content of steel may be lower and the coating higher, see Table 3. ** Exists in corrosivity categories C3H-C4H only when zinc paint is needed. *** Exists in fire protected structure only R ; H400, H411, H413 Measurements are done to a level of 0.02 μg/g ( %). Concentrations below this degree of measuring accuracy cannot be determined. According to supplier notifications, none of the constituent substances within the whole product exceeds the limits of the EU s chemical regulation (REACH) and recommendations phasing out hazardous substances in the building sector such as the requirements of BASTA (2014: A2) and Byggvarubedömningen (Building Material Assessment, BVB, 2013), Swedish Building Product Declarations (Föreningen för Byggvarudeklarationer, BPD 3, 2007) and the priority list in Norway. No product contains substances restricted under REACH or included on the candidate list (SVHC). Table2. Average and maximum content (%) of coating of total product weight in steel structures Corrosivity category* Trusses and structural tubes and sections, average content (%) Trusses and structural tubes and sections, maximum content (%) WQ Beam, average content (%) C C C C C5L(H), C5M(H)** Fire protected C * According to EN ISO ** Typically in bridge superstructures WQ Beam, maximum content (%) 4

5 Production The steel in the steel structures under this environmental product declaration is sourced from Ruukki s steel works in Raahe, Finland. The amount of scrap steel used varies between around % of the steel charge depending on the steel grade and method of manufacture. In 2012, the average value was 20%. Use of energy and raw materials has been optimised in steel production. When scrap steel is used instead of virgin raw materials in iron production, the carbon dioxide emissions originating in steel production decrease accordingly. Steelmaking at Ruukki uses scrap material from Ruukki s own production processes and material sourced from the scrap steel market. For reasons of process technology, the content of scrap steel in blast-furnace-based steel production cannot exceed around 30%. In addition, the amount of scrap steel in steel production is limited due to its availability. Once steel has been made, it can be recycled endlessly without weakening its properties. Steel plates, tubes or sections are first cut by flame cutting or sawing to the required length and then welded together, shot blasted and coated with paint. Surface treatment causes volatile organic compounds (VOC) emissions of approximately 5 kg per tonne produced. VOC emissions per tonne depend, however, on the weight of the structure and the chosen painting system. Ruukki aims to employ the best available technology in all its production processes. Pre-fabricated steel structures enable the amount of construction site waste to be considerably reduced. On the construction site, the structures are welded together or fastened with nuts and bolts. Packaging Ruukki s steel frames and bridge superstructures are all individual products and transportation is planned separately for each product. Wooden props, cardboard edge protection beds and metal bands and chains are used to package the loads for transportation. Sensitive surfaces can be wrapped in plastic to prevent contamination; otherwise the frames and structures are not wrapped but are cleaned on site after transportation if necessary. All packaging materials are recyclable. Packaging materials are sorted at the production site and at construction sites sorting is done according to customer requests. Figure 1: A typical transportation of steel trusses, loaded on a truck, ready for delivery to the construction site. Sourcing and transportation The general terms and conditions of all sourcing contracts require compliance with Ruukki s Code of Conduct. Also ethical values, environmental concerns and energy efficiency are weighed up when choosing suppliers. Raw materials are mostly transported to production sites by road. Finished products are transported by truck, rail and boat combined. Ruukki s logistics unit is responsible for most of Ruukki s transportation of raw materials and products. 5

6 Ruukki s logistics unit manages environmental concerns through a certified environmental management system. Ruukki aims to increase the share of logistics contracts with partners who have signed up for energy efficiency agreements in the logistics and transport sector. Around 85% of Ruukki s land transportations per tonne of products are carried by a partner signatory to energy efficiency agreements. Logistics firms currently outside energy efficiency agreements are regularly encouraged to sign up for an agreement. Ruukki s international partners have certified environmental management systems. Logistics aims to optimise transport and maximise payloads as efficiently as possible. Recycling and waste processing Steel is a fully-recyclable material and is an important raw material for new construction. Prefabricated structures can be re-used. No hazardous wastes originate from steel structures. Prefabrication results in close to zero waste at the construction site. Waste materials originating from construction, renovation and demolition are sorted and steel scrap is returned to the steel industry to be reused. Scrap steel has a strong market position: an average of 95% of the steel removed from buildings at the end of their lifecycle is used in the production of new steel. No hazardous waste is formed from end products and steel material does not harm the environment in the place of use. According to the European Waste Catalogue, the waste code for steel products manufactured by Ruukki after their useful life is (iron and steel). All packaging materials for steel products can be recycled. Information about safe installation and use Steel structures are pre-fabricated elements assembled by bolts and welds. Ruukki s steel structures can be installed quickly and safely. Fast installation and easy lifecycle maintenance reduce costs and adverse environmental impacts. Safety risks should always be evaluated by the project manager and site manager before installation startup. The local site manager is responsible for informing installation people about safe working practices and the personal protective equipment required. Safety Ruukki requires proper working clothes to be worn to avoid cuts from sharp steel parts when installing Ruukki s products. Safety shoes, helmet, visibility workwear and protective eyeglasses are mandatory when working with Ruukki. Protective gloves suitable for each work phase are recommended at all times to protect the hands. Ear protection should be used when needed. Welding and grinding requires the wearing of fire-resistant workwear, respiratory protective equipment and appropriate eye and hearing protection. When grinding painted structures, the risk to other workers must be evaluated and if necessary, the area must be restricted during this work phase due to particle emissions. When painting, including touch-up painting, proper respiratory protective equipment and glasses must be worn in addition to the working clothes above. For environmental safety reasons, all chemicals including paint should always be kept safe to hinder any contamination to soil and water. Emergency equipment, such as absorbent, are kept at site. Paint splashes must be prevented from contaminating the environment, especially when painting near waterways. Maintenance The coating must be regularly checked and impurities removed. The coating can be repaired using maintenance paint. The service life and maintenance planning is made according to standard ISO and customer requirements. In steel frames, the durability of the paint coatings before maintenance painting is divided into environmental classes (corrosivity categories) as follows. L low, 2 5 years M medium, 5 15 years high, H high, over 15 years The service life of steel structures has been measured in accordance with EN standards. More detailed information about the design principles for service life can be found in, inter alia, standards EN 1990 and EN ISO In bridge superstructures, the minimum durability of the paint coating is 25 years. With proper, regular maintenance the service life of a steel frame or bridge is 50 years. 6

7 Environmental profile Raw material supply (A1) Transport (A2) Production (A3) Transport (A4) On-site installation (A5) Use stage (B1-B7) Demolition (C1) Transport (C2) Recycling (D) Steel Welding consumables, paints, etc. Production of steel structures: Pre-cleaning, drilling, cutting, welding, coating, packing Returning scrap steel as a raw material to the steelmaking process Energy Waste processing (C3-C4) Waste disposal Figure 2. System boundaries of lifecycle assessment. The chart describes the lifecycle stages of steel structures. Lifecycle assessment excludes the lifecycle stages in a grey background. This environmental product declaration covers the lifecycle of the product from cradle to factory gate, i.e. information modules A1, A2, A3, including an end-of-life recycling rate of 90% for steel, i.e. the external lifecycle impacts from information module D ( cradle to gate with options ). This means that a burden is allocated for the steel scrap that is used as an input to the steel making process, and a credit for the endof-life (EoL) steel that is recycled. The lifecycle assessment in the environmental production declaration does not include information in the building stage (A4 A5), the use and operational stage (B1 B5; B6 B7) nor the demolition stage (C1 C4). The impact of recycling has been calculated using worldsteel s (World Steel Association) LCA data so that the compensation is the difference between the primary and secondary production of a steel slab perceived with the acquisition of the recycling process kg of recycled steel is needed to produce 1 kg of steel in secondary production. Ruukki uses an average of 20% scrap steel in its steel production. The benefits and loads of the scrap steel used by Ruukki are accounted for in module D in accordance with worldsteel s lifecycle model. To avoid double calculation, these are not reported separately as use of secondary material in accordance with standard EN The lifecycle benefits of the by-products originating in steel production have been allocated to steel production in accordance with worldsteel s lifecycle model so that the benefits are seen in the lifecycle information for Raw material supply (A1). Allocation of by-products is calculated as reducing environmental impacts in the production of hot-rolled steel by 5-10%, and an average of 8%. The table below shows the environmental indicators based on a lifecycle analysis of steel structures. All values apply to 1 kg of steel structures. 7

8 Table 3. The environmental profile of welded and coated sections, trusses and beams made of hot-rolled plate, sheet and coil Parameter Unit Product stage Benefits and loads beyond the system A1 A2 A3 Product boundary Raw Transport Manufacturing stage Total D material Re-use, recovery, supply recycling potential Parameters describing environmental impacts Global warming potential GWP kg CO 2 equiv Depletion potential of the stratospheric ozone layer ODP Acidification potential of soil and water sources AP kg CFC-11 equiv 9.73x x x x x10-08 kg SO 2 equiv 4.58x x x x x10-2 Eutrophication potential EP kg (PO 4 ) -3 equiv 5.00x x x x x10-5 Formation potential of tropospheric ozone POCP Abiotic depletion potential of tropospheric ozone (ADP-elements) Abiotic depletion potential ADP-fossil fuels kg ethene equiv 3.77x x x x x10-4 kg SB equiv 1.26x x x x x10-5 Parameters describing resource use and primary energy Use of renewable primary energy used as energy carrier Use of renewable primary energy resources used as raw material Total use of renewable primary energy resources primary energy used as energy carrier primary energy used as raw material Total use of non-renewable primary energy resources Use of secondary material kg Use of renewable secondary fuels secondary fuels Net use of fresh water m Other environmental information describing waste categories Hazardous waste disposed kg 5.37x x x x10-3 Non-hazardous waste disposed kg 4.12x x x x10-2 Radioactive waste disposed kg 2.97x x x x10-4 Other environmental information describing output flows Parameter Unit Total Components for re-use kg - Materials for recycling kg - Materials for energy recovery kg - Exported energy MJ per energy carrier

9 Table 4. The environmental profile of welded and coated trusses and beams made of cold-formed structural tubes and sections Parameter Unit Product stage Benefits and loads beyond the system A1 A2 A3 Product boundary Raw material supply ing Transport Manufactur- stage Total D Re-use, recovery, recycling potential Parameters describing environmental impacts Global warming potential GWP kg CO 2 equiv Depletion potential of the stratospheric ozone layer ODP Acidification potential of soil and water sources AP kg CFC-11 equiv 1.08x x x x x10-8 kg SO 2 equiv 5.04x x x x x10-3 Eutrophication potential EP kg (PO 4 ) -3 equiv 5.17x x x x x10-5 Formation potential of tropospheric ozone POCP Abiotic depletion potential of tropospheric ozone (ADP-elements) Abiotic depletion potential ADP-fossil fuels kg ethene equiv 4.03x x x x x10-4 kg SB equiv 1.31x x x x x10-5 Parameters describing resource use and primary energy Use of renewable primary energy used as energy carrier Use of renewable primary energy resources used as raw material Total use of renewable primary energy resources primary energy used as energy carrier primary energy used as raw material Total use of non-renewable primary energy resources Use of secondary material kg Use of renewable secondary fuels secondary fuels Net use of fresh water m Other environmental information describing waste categories Hazardous waste disposed kg x Non-hazardous waste disposed kg 3.51x x x Radioactive waste disposed kg 3.70x x x x10-4 Other environmental information describing output flows Parameter Unit Total Components for re-use kg - Materials for recycling kg - Materials for energy recovery kg - Exported energy MJ per energy carrier

10 CFI.001EN/ /AN This environmental product declaration provides information about the environmental impacts of Ruukki s products. The declaration is based on the requirements of standards EN A1:2014, ISO 14025:2010 and ISO 14040:2006. An environmental product declaration contains information about the raw materials, energy consumption, emissions originating during production and about product recyclability. Ruukki Construction serves customers in the construction business. We deliver products and services ranging from design to installation to promote the business of our corporate customers. Ruukki s corporate responsibility is defined in Ruukki s strategy, values, code of conduct, policies and management system. Ruukki s production sites operate in conformance with certified ISO environmental management and ISO 9001 quality management systems. Ruukki aims at continuous improvement and energy efficiency in all operations and customer solutions. Ruukki Construction is a division of SSAB, our brands are Ruukki and Plannja. The most recent information about Ruukki s products and services, product safety and use and environmental and social responsibility can be found on Ruukki s website at www. ruukki.com. Ruukki Construction Oy, Suolakivenkatu 1, FI Helsinki, , Copyright 2014 Rautaruukki Corporation. All rights reserved.