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 (IBU) Institut Bauen und Umwelt (IBU) EPD-KSK-2012611-E 18.08.2012 17.08.2017 Vitreous Kaleseramik Çanakkale Kalebodur Ceramic Industries Inc. www.bau-umwelt.com
General information Kaleseramik Çanakkale Kalebodur Ceramic Industries Inc. Programme holder IBU - Institut Bauen und Umwelt e.v. Rheinufer 108 D-53639 Königswinter Declaration number EPD-KSK-2012611-E This Declaration is based on the Product Category Rules: Part B: Requirements on the EPD for Sanitary ceramics, 06-2011 (PCR tested and approved by the independent expert committee, SVA) Issue date 18.08.2012 Valid to 17.08.2017 Vitreous Owner of the Declaration Kaleseramik Çanakkale Kalebodur Ceramic Industries Inc. Büyükdere Caddesi Kaleseramik Binası 34330 Levent, İstanbul, Turkey Declared product / Declared unit Vitreous / 1 tonne Scope: 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. Verification The CEN standard EN 15804 serves as the core PCR. Verification of the EPD by an independent third party as per ISO 14025 internally x externally Prof. Dr-Ing. Horst J. Bossenmayer (President of the Institut Bauen und Umwelt) Prof. Dr.-Ing. Hans-Wolf Reinhardt (Chairman of the independent expert committee, SVA) 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; 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 privatelyowned 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 and Safety and ISO 14001 Environmental Management systems in place. 2 Environmental Product Declaration Kaleseramik Çanakkale Kalebodur Ceramic Industries Inc. Vitreous
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. - Harkord-Cracking Test according to TL 20: Compliant - Water absorption test according to EN 997 (max 0.5%): Compliant - Resistance to chemicals and staining agents according to NFD 14-508:1985: Compliant - Surface hardness test to TS 605: Compliant - Resistance to acids according to NFD 14-508:2012: Compliant 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. System boundary This is a cradle to gate EPD. 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. 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. - Resistance to hot alkalines according to NFD 14-507:2012: 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. 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: Comparability 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. 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. 3 Environmental Product Declaration Kaleseramik Çanakkale Kalebodur Ceramic Industries Inc. Vitreous
LCA: Results DESCRIPTION OF THE SYSTEM BOUNDARY (X = INCLUDED IN LCA; MND = MODULE NOT DECLARED) PRODUCT STAGE CONSTRUC- TION PRO- CESS STAGE USE STAGE END OF LIFE STAGE BENEFITS AND LOADS BE- YOND THE SYSTEM BOUNDARIES Raw material supply Transport Transport Constructioninstallation process Use Maintenance Repair Replacement A1 A2 A3 A4 A5 B1 B2 B3 B4 B5 B6 B7 C1 C2 C3 C4 D Refurbishment Operational energy use Operational water use De-construction demolition Transport Waste processing Disposal Reuse- Recovery- Recyclingpotential X X X MND MND MND MND MND MND MND MND MND MND MND MND X MND RESULTS OF THE LCA - ENVIRONMENTAL IMPACT: 1 tonne of Vitreous Parameter Unit A1 A2 A3 C4 Global warming potential [kg CO 2 Eq.] 183 41.3 1344 16.0 Depletion potential of the stratospheric ozone layer [kg CFC11 Eq.] 1.89E-05 5.87E-06 1.44E-04 4.22E-06 Formation potential of tropospheric ozone photochemical oxidants EoL [kg ethene Eq.] 0.0828 0.0504 0.693 0.0362 Acidification potential of land and water [kg SO 2 Eq.] 0.609 0.153 1.94 0.0908 Eutrophication potential [kg PO 4 3-- Eq.] 0.352 0.0449 0.923 0.0233 Abiotic depletion potential for non fossil resources [kg Sb Eq.] 1.40 0.309 11.4 0.193 Abiotic depletion potential for fossil resources [MJ Eq.] 3072 703 23068 444 RESULTS OF THE LCA - RESOURCE USE: 1 tonne of Vitreous Parameter Unit A1 A2 A3 C4 Use of renewable primary energy excluding renewable primary energy resources used as raw materials [MJ] 140 9.98 2204 3.30 Use of renewable primary energy resources used as raw materials [MJ] 0 0 0 0 Total use of renewable primary energy resources [MJ] 140 9.98 2204 3.30 Use of non renewable primary energy excluding non renewable primary energy resources used as raw [MJ] 2621 667 22807 428 materials Use of non renewable primary energy resources used as raw materials [MJ] 0 0 0 0 Total use of non renewable primary energy resources [MJ] 2621 667 22807 428 Use of secondary material [kg] - - - - Use of renewable secondary fuels [MJ] - - - - Use of non renewable secondary fuels [MJ] - - - - Use of net fresh water [m³] 9.22 0.357 9.44 0.467 RESULTS OF THE LCA OUTPUT FLOWS AND WASTE CATEGORIES: 1 tonne of Vitreous China Ceramic Sanitaryware Parameter Unit EoL EoL A1 A2 A3 C4 Hazardous waste disposed [kg] - - 0.0582 - Non hazardous waste disposed [kg] - - 293 1000 Radioactive waste disposed [kg] - - - - Components for re-use [kg] - - - - Materials for recycling [kg] - - - - Materials for energy recovery [kg] - - - - Exported energy per energy carrier [Typ] [MJ] - - - - 4 Environmental Product Declaration Kaleseramik Çanakkale Kalebodur Ceramic Industries Inc. Vitreous
References NFD 14 506:1985 Sanitary Appliances - Resistance To Domestical Chemical Agents And Resistance To Stains Of The Enamelled Surfaces - Conventional Test Method NFD 14 508:2012 Sanitary Appliances - Resistance To Domestical Chemical Agents And Resistance To Stains Of Enamelled Surfaces - Conventional Test Method 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 Ecoinvent Ecoinvent Centre www.ecoinvent.org SimaPro SimaPro LCA Package, Pré Consultants, the Netherlands www.pre-sustainability.com ISO 14025 DIN EN ISO 14025:2009-11: Environmental labels and declarations Type III environmental declarations Principles and procedures EN 15804 DIN EN 15804:2012-04: Sustainability of construction works Environmental Product Declarations Core rules for the product category of construction products ISO 9001 DIN EN ISO 9001:2008, Quality Management System-Requirements ISO 14001 DIN EN ISO 14001:2004, Environmental Management Systems-Requirement OHSAS 18001 DIN EN OHSAS 18001:2007, Occupational Health and Safety Management System 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), 2011-06 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 2011 www.bau-umwelt.de 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 5 Environmental Product Declaration Kaleseramik Çanakkale Kalebodur Ceramic Industries Inc. Vitreous
Publisher Institut Bauen und Umwelt e.v. Tel. +49 (0)2223 2966 79-0 Rheinufer 108 Fax +49 (0)2223 2966 79-0 53639 Königswinter E-mail info@bau-umwelt.com Germany Web www.bau-umwelt.com Programme holder Institut Bauen und Umwelt e.v. Tel. +49 (0)2223 2966 79-0 Rheinufer 108 Fax +49 (0)2223 2966 79-0 53639 Königswinter E-mail info@bau-umwelt.com Germany Web www.bau-umwelt.com Owner of the Declaration Kaleseramik Çanakkale Kalebodur Ceramic Industries Inc. Tel. +90 212 371 52 53 Büyükdere Caddesi Kaleseramik Binası Fax: +90 212 269 17 42 34330 Levent, İstanbul E-mail: info@kale.com.tr Turkey Web www.kale.com.tr Author of the Life Cycle Assessment Metsims Sustainability Consulting Tel. +90 534 499 32 40 Veko Giz Plaza, Meydan Sk. No:3 K.13 Fax: +90 212 705 36 36 34396 Maslak, İstanbul, Turkey E-mail: info@metsims.com 4 Clear Water Place Web www.metsims.com Oxford, OX2 7NL, United Kingdom Tel. +44 755 735 14 76