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An Industry Average Cradle-to-Gate Life Cycle Assessment of Glass Mat Gypsum Panels for the USA and Canadian Markets

EPD Project Report Commissioner: Gypsum Association EPD Program Operator: ASTM International August 2016

Athena Sustainable Materials Institute

Industry Average LCA of Glass Mat Gypsum Panels ii

General Summary This life cycle assessment (LCA) report for environmental product declaration (EPD) presents industry average results for two thicknesses of gypsum based glass mat panels as produced by Gypsum Association members in the US and Canada. The LCA has been completed to support a Type III Environmental Product Declaration (EPD) for glass mat gypsum panels conforming to ASTM C1177 Standard Specification for Glass Mat Gypsum Substrate for Use as Sheathing. Specifically, this industry average LCA has been completed in conformance with ISO 14040/44 standards [2], [3] and in accordance with ASTM International (ASTM) product category rules (PCR) for preparing an environmental product declaration for glass mat gypsum panels [1] and ASTM International’s EPD program operator rules [8]. This EPD project report (underlying LCA report for EPD development purposes) was commissioned by the Gypsum Association and its members and is certified by ASTM International to conform to the requirements of ISO 14040 [2], 14044 [3],14025 [5] and 21930 [6]. General Summary Owner of the EPD

Gypsum Association (GA) 6525 Belcrest Road, Suite 480 Hyattsville, MD 20782 Link (URL): www.gypsum.org [email protected] The GA is a not-for-profit trade association founded in 1930. Its mission is to promote the use of gypsum while advancing the development growth, and general welfare of the gypsum industry in the U.S. and Canada on behalf of its member companies. GA members include all the active gypsum board (panel) manufacturers in the U.S. and Canada. Each GA member company provided both LCI and meta-data for the reference year 2013. GA members, with the inclusion of their Canadian holdings and affiliates, produce and ship over 95% of the glass mat gypsum panel sheathing consumed in the USA and Canada. The owner of the declaration is liable for the underlying information and evidence.


Industry Average LCA of Glass Mat Gypsum Panels iii

General Summary GA Member Companies Corporate Locations

American Gypsum Company LLC 3811 Turtle Creek Blvd., Suite 1200 Dallas, TX 75219, USA Member Link (URL): http://www.americangypsum.com/

CertainTeed Gypsum, Inc. CertainTeed Gypsum Canada, Inc. 20 Moores Road Malvern, PA 19355, USA Member Link (URL): http://www.certainteed.com/gypsum

Continental Building Products Operating Company, LLC 12950 Worldgate Drive, Suite 700 Herndon, VA 20170, USA Member Link (URL): http://www.continental-bp.com/en/

Georgia-Pacific Gypsum LLC 133 Peachtree Street NE Atlanta, GA 30303, USA Member Link (URL): http://www.buildgp.com/Georgia-Pacific-Gypsum

National Gypsum Company 2001 Rexford Road Charlotte, North Carolina 28211, USA Member Link (URL): http://nationalgypsum.com/


Industry Average LCA of Glass Mat Gypsum Panels iv

General Summary

PABCO® Gypsum a division of PABCO® building products, LLC 10600 White Rock Road, Suite 100 Rancho Cordova, CA 95670, USA Member Link (URL): http://www.pabcogypsum.com/

United States Gypsum Company 550 West Adams Street Chicago, IL 60661-3676, USA Member Link (URL): http://www.usg.com/content/usgcom/en.html CGC INC. 350 Burnhamthorpe Road West 5th Floor Mississauga, ON, L5B 3J1, Canada Member Link (URL): http://www.usg.com/content/usgcom/en_CA_east.html

Product Group and Name Glass Mat Gypsum Panel

Product Definition Glass mat gypsum panels (known as glass mat panels) are designed to be used as exterior substrate or sheathing for weather barriers. The substrates consist of a noncombustible water-resistant gypsum core, surfaced with glass mat partially or completely embedded in the core [9].

Product Category Rules (PCR) ASTM International, Product Category Rules For Preparing an Environmental Product Declaration For Glass Mat Gypsum Panels, August 2016 [1].

Certification Period 08/17/2016 – 08/17/2021 Declared Unit 1,000 square feet (1MSF) of Glass Mat Gypsum Panel

with a nominal finished thickness of ½” and 5/8”

ASTM Declaration Number EPD-038


Industry Average LCA of Glass Mat Gypsum Panels v

EPD Information Program Operator

ASTM International

Declaration Holder

Gypsum Association (GA)

Product group Glass Mat Gypsum Panel

Date of Issue 08/17/2016

Period of Validity 5 years

Declaration Number EPD- 038

Declaration Type A “cradle-to-gate” EPD for Glass Mat Gypsum Panels manufactured by GA members. Activity stages or information modules covered include production with the product ready for shipment at the manufacturing plant (modules A1 to A3). The declaration is intended for use in Business-to-Business (B-to-B) communication. Applicable Countries United States and Canada Product Applicability Glass Mat Gypsum Panels are typically used as exterior building envelope sheathing providing weather barriers, mold and fire resistance for new construction or renovation work. Content of the Declaration This declaration follows Section 11; Content of the EPD, ASTM International, Product Category Rules For Preparing an Environmental Product Declaration for Glass Mat Gypsum Panels, August 2016. This EPD was independently verified

Tim Brooke 100 Barr Harbor Drive, PO Box C700 West Conshohocken, PA 19428-2959, USA www.astm.org/EPDs.htm

by ASTM in accordance with ISO 14025:

Internal External

X


Industry Average LCA of Glass Mat Gypsum Panels vi

EPD Project Report Information EPD Project Report

An Industry Average Cradle-to-Gate Life Cycle Assessment of Glass Mat Gypsum Panel for the USA and Canadian Markets, August 2016.

Prepared by

Lindita Bushi, Jamie Meil and Grant Finlayson Athena Sustainable Materials Institute 119 Ross Avenue, Suite 100 Ottawa, Ontario, Canada K1Y 0N6 email: [email protected] www.athenasmi.org

This EPD project report was independently verified by in accordance with ISO 14025 and the reference PCR:

Thomas P. Gloria, Ph.D. Industrial Ecology Consultants 35 Bracebridge Rd. Newton, MA 02459-1728 direct: 617.553.4929 mobile: 857.636.0585 email: [email protected]

PCR Information Program Operator

ASTM International

Reference PCR

ASTM International, Product Category Rules For Preparing an Environmental Product Declaration For Glass Mat Gypsum Panels

Date of Issue August 2016 PCR review was conducted by:

Gary Jakubcin, B&G Jakubcin and Associates, LLC (Chairperson) email: [email protected] Steven Butler, ACG Materials Mark Flumiani, Innogyps


Industry Average LCA of Glass Mat Gypsum Panels vii

Glossary of Terms

Based on ISO 14040/44:2006 [2], [3] – Terms and Definition Section. Allocation: Partitioning the input or output flows of a process or a product system between the product system under study and one or more other product systems. Life Cycle: Consecutive and interlinked stages of a product system, from raw material acquisition or generation from natural resources to final disposal. 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 for a product system throughout the life cycle of the product. Life Cycle Interpretation: Phase of life cycle assessment in which the findings of either the inventory analysis or the impact assessment, or both, are evaluated in relation to the defined goal and scope in order to reach conclusions and recommendations. Life Cycle Inventory (LCI): Phase of Life Cycle Assessment involving the compilation and quantification of inputs and outputs for a product throughout its life cycle. Product system: Collection of unit processes with elementary and product flows, performing one or more defined functions, and which models the life cycle of a product. System boundary: Set of criteria specifying which unit processes are part of a product system. Note: the term system boundary is not used in this International Standard in relation to LCIA. System expansion: Expanding the product system to include the additional functions related to the co-products, taking into account the requirements of 4.2.3.3. Based on ISO 14021:1999 [4]- Clause 7.8 Recycled content Recovered material: Material that would have otherwise been disposed of as waste or used for energy recovery but has instead been collected and recovered as a material input, in lieu of new primary material, for a recycling or a manufacturing process.


Industry Average LCA of Glass Mat Gypsum Panels viii

Pre-consumer material: Material diverted from the waste stream during a manufacturing process. Excluded is reutilization of materials such as rework, regrind or scrap generated in a process and capable of being reclaimed within the same process that generated it. Post-consumer material: Material generated by households or by commercial, industrial and institutional facilities in their role as end-users of the product that can no longer be used for its intended purpose. This includes returns of material from the distribution chain. Based on ISO 14025:2006 [5] - Clause 3 Terms and definitions Type III Environmental Product Declaration (EPD): providing quantified environmental data using predetermined parameters and, where relevant, additional environmental information Note 1 the predetermined parameters are based on the ISO 14040 series of standards. Note 2 the additional environmental information may be quantitative or qualitative. Product Category Rules (PCR): set of specific rules, requirements and guidelines for developing Type III environmental declarations for one or more product categories. Based on ISO 21930:2007 [6] - Clause 3 Terms and definitions Building product: goods or services used during the life cycle of a building or other construction works. Declared unit: quantity of a building product for use as a reference unit in an EPD, based on LCA, for the expression of environmental information needed in information modules. Information module: compilation of data to be used as a basis for a type III environmental declaration, covering a unit process or a combination of unit processes that are part of the life cycle of a product.


Industry Average LCA of Glass Mat Gypsum Panels ix

Table of Contents GeneralSummary.................................................................................................................................ii

GlossaryofTerms..............................................................................................................................vii

TableofContents.................................................................................................................................ix

ListofFigures..........................................................................................................................................x

ListofTables.........................................................................................................................................xi

AcronymsandAbbreviations........................................................................................................xii

1 Introduction............................................................................................................................14

2 StudyGoals...............................................................................................................................142.1 GoalsoftheStudy.............................................................................................................................142.2 IntendedApplicationsandAudience........................................................................................142.3 ComparativeAssertions.................................................................................................................14

3 ProductIdentification..........................................................................................................153.1 ProductDefinition...........................................................................................................................153.2 ProductStandard.............................................................................................................................153.3 MaterialContent...............................................................................................................................16

4 DeclaredUnit&SystemBoundary...................................................................................17

5 LifeCycleInventory..............................................................................................................185.1 DataCollectionandRepresentativeness..................................................................................185.2 LCIDataSourcesandDataQuality.............................................................................................195.3 Cut-offCriteriaandAllocationRules.........................................................................................235.4 EnvironmentalCategoryIndicators...........................................................................................245.5 ProductManufacturingLifeCycleInventory..........................................................................25

6 LifeCycleImpactAssessment............................................................................................30

7 Interpretation.........................................................................................................................33

8 AdditionalEnvironmentalInformation.........................................................................35

9 DeclarationTypeandProductAverageDeclaration.................................................36

10 DeclarationComparabilityLimitationStatement......................................................36

12 References................................................................................................................................37


Industry Average LCA of Glass Mat Gypsum Panels x

List of Figures Figure 1: Glass Mat Gypsum Panels ........................................................................................... 15Figure 2: Product Stage (Module A1 to A3) System Boundary ................................................... 18Figure 3: EPD Results by Information Module – 1 MSF of ½” GMGP – % Basis ....................... 31Figure 4: EPD Results by Information Module – 1 MSF of 5/8” GMGP – % Basis ..................... 31


Industry Average LCA of Glass Mat Gypsum Panels xi

List of Tables Table 1: Weighted Average Material Content for 1MSF of GMGPs by Thickness ...................... 16Table 2: Summary of Data Sources and Quality [SimaPro v.8.1.0.60, April 2016] ..................... 20Table 3: LCIA Category Indicators .............................................................................................. 24Table 4 Parameters Describing Resource Use and Waste Categories ...................................... 24Table 5: Inputs/Outputs – 1 MSF of GMGPs by Thickness (A3 Manufacturing) ......................... 26Table 6: Weighted Average Inbound/Outbound Transportation Modes and Distances (one-way)

.................................................................................................................................. 29Table 7: Product Stage (A1-A3) - EPD Results – 1 MSF of ½” and 5/8” GMGP ......................... 30Table 8: Contribution Analysis – 1 MSF of ½” GMGP Product System – Absolute and % Basis 32Table 9: Contribution Analysis – 1 MSF of 5/8” GMGP Product System – Absolute and % Basis

.................................................................................................................................. 32Table 10: Sensitivity Analysis – EPD results, 1 MSF of ½” GMGP Product System- Absolute and

% basis ..................................................................................................................... 34Table 11: Sensitivity Analysis – EPD results, 1 MSF of 5/8” GMGP Product System- Absolute

and % basis .............................................................................................................. 34


Industry Average LCA of Glass Mat Gypsum Panels xii

Acronyms and Abbreviations ADP Abiotic Depletion Potential ASTM American Society for Testing and Materials B2B Business-to-Business Btu British thermal units C2G Cradle-to-Gate CED Cumulative Energy Demand CF Characterization Factor CFCs Chlorofluorocarbons CFC-11 Trichlorofluoromethane CO2 Carbon Dioxide EOL End-of-Life EPDs Environmental Product Declarations GA Gypsum Association G2G Gate-to-Gate GMGP Glass Mat Gypsum Panel(s) GWP Global Warming Potential H+ Hydrogen ion HHV Higher Heating Value HWD Hazardous waste disposed IC Impact Categories IPCC International Panel on Climate Change ISO International Organization for Standardization kg Kilogram kJ Kilojoules km Kilometer kWh kilowatt hours LCA Life Cycle Assessment LCI Life Cycle Inventory LCIA Life Cycle Impact Assessment LPG Liquefied Propane Gas MC Moisture content MJ Mega joule MSF Thousand Square Feet N Nitrogen NERC The North American Electric Reliability Corporation NHWD Non-Hazardous Waste Disposed NOx Nitrogen Oxides NPRI Canadian National Pollutant Release Inventory NRMS Non-Renewable Material Resources NRPE Non-Renewable Primary Energy Resources NRPE-F Non-Renewable Primary Energy Resources, fossil


Industry Average LCA of Glass Mat Gypsum Panels xiii

NRPE-N Non-Renewable Primary Energy Resources, nuclear NRPE-M Non-Renewable Primary Energy Resources, used as raw materials (feedstock) NRSF Non-Renewable Secondary Fuels NUFW Net Use (consumption) of Fresh Water O3 Ozone OSHA Occupational Safety & Health Administration P Phosphorous PCR Product Category Rules PM2.5 Particulate Matter less than or equal to 2.5 micrometers in diameter PM10 Particulate Matter less than or equal to 10 micrometers in diameter RMS Renewable Material Resources RPE Renewable Primary Energy Resources RPE-M Renewable Primary Energy Resources, used as raw materials (feedstock) RSF Renewable Secondary Fuels RWD Radioactive waste disposed SM Secondary Material SO2 Sulfur dioxide STMP Sodium Trimetaphosphate TRACI Tool for the Reduction and Assessment of Chemical and Other Environmental

Impacts UN CPC United Nations Central Product Classification US EPA United States Environmental Protection Agency VOCs Volatile Organic Compounds


Industry Average LCA of Glass Mat Gypsum Panels 14

1 Introduction Life cycle assessment (LCA) is an analytical tool used to comprehensively quantify and interpret the energy and material flows to and from the environment over the entire life cycle of a product, process, or service [2], [3]. Environmental flows include emissions to air, water, and land, as well as the consumption of energy and material resources. By including the impacts throughout the product life cycle, LCA provides a comprehensive view of the environmental aspects of the product. It is acknowledged that this particular LCA is conducted for the production of Glass Mat Gypsum Panels (GMGPs) ready for shipment at the plant gate in the USA and Canada and as such has a business-to-business (B2B) focus. That said the study demonstrates the Gypsum Association members’ commitment to transparently sharing the environmental footprint of GMGPs and in support of generating an EPD for users of GMGPs both in the USA and Canada.

2 Study Goals

2.1 Goals of the Study This is a sector-driven initiative by the Gypsum Association (GA) and its members to conduct an LCA to support the development of an EPD according to ISO 14025:2006 [5], ISO 21930:2007 [6] and EN 15804:2012 [7] for GMGPs, as manufactured and distributed in North America (United States and Canada) by GA members.

2.2 Intended Applications and Audience This EPD is intended for use in Business-to-Business (B-to-B) communication. The intended audience for this EPD include GA member companies, their suppliers, architectural, engineering, and specifying professionals, LCA practitioners and tool developers, academia, governmental organizations, policy makers and other interested value chain parties who require reliable information on GMGPs.

2.3 Comparative Assertions This EPD project report (underlying LCA report for EPD development purposes) does not include comparative assertions; however, the subsequent EPD may lead to future comparative studies intended to be disclosed to the public. LCAs and EPDs not covering all life cycle stages or based on a different PCR are examples of studies and EPDs offering limited comparability. This EPD project report was independently verified by Thomas P. Gloria, Ph.D., Industrial Ecology Consultants, as per ISO 14025 (see Clause 8.1.3) [5] and the reference PCR requirements [1].



3 Product Identification

3.1 Product Definition GMGPs UNSPSC Code 30161500, as defined in ASTM C1177 are designed to be used as an exterior substrate or sheathing for weather barriers [9]. The substrates consist of a noncombustible water-resistant gypsum core, surfaced with a glass mat partially or completely embedded in the core [9]. Typically GMGPs are 4' wide and 8' length panels (4'×8') produced with a square edge and are compatible with most exterior wall and roof applications. GMGP may be available in other lengths and can vary in thickness and fire rating properties depending on the application (e.g., tile backer board). The focus of this industry average LCA study is exterior sheathing applications for panels with a finished nominal thickness of ½" and 5/8". GMGPs are also proprietary products and while they all employ glass matting and a water-resistant gypsum core the panel composition varies across manufacturers.

Figure 1: Glass Mat Gypsum Panels

3.2 Product Standard Applicable product standards for GMGPs (UNSPSC Code 30161500) include: • ASTM C1177 Standard Specification for Glass Mat Gypsum Substrate for Use as

Sheathing • ASTM C1658 Standard Specification for Glass Mat Gypsum Panels • ASTM C11 Terminology Relating to Gypsum and Related Building Materials and Systems • ASTM C22 Specification for Gypsum • ASTM C473 Test Methods for Physical Testing of Gypsum Panel Products • ASTM C1264 Specification for Sampling, Inspection, Rejection, Certification, Packaging,

Marking, Shipping, Handling, and Storage of Gypsum Panel Products • ASTM E119 Test Methods for Fire Tests of Building Construction and Materials



3.3 Material Content Table 1 below presents the weighted average composition by input material for one thousand square feet (1MSF) of ½" and 5/8" GMGPs as derived from the GA member facilities LCI data collection for the reference year 2013.

Table1:WeightedAverageMaterialContentfor1MSFofGMGPsbyThickness

Inputs Units ½"GMGP 5/8"GMGP

Gypsummaterialandglassmatting

Naturalgypsumore Pounds 1,440 1,816Pre-consumergypsum-FGDsyntheticgypsum

Pounds 205 275Post-consumergypsum1 Pounds 19.1 23.6Glassmatting Pounds 99.0 99.0

Additives(bothdryandwet)

Starch Pounds 0.4 0.4Fiberglass(otherthanmattingabove) Pounds 2.8 4.2Dispersant Pounds 2.6 2.8Retarder Pounds 0.3 0.3PotassiumSulfate Pounds 2.2 2.3Dextrose Pounds 0.01 0.00BoricAcid Pounds 0.09 0.16LandPlaster Pounds 1.2 1.5Foamingagent(soap) Pounds 0.4 0.4Ballmill(BM)accelerator Pounds 2.6 2.6EdgePaste Pounds 2.2 2.3Flyash Pounds 0.6 0.6Siliconeproducts Pounds 8.8 9.8Wax Pounds 0.8 0.9Biocide,sodiumomadine,sodiumtrimetaphosphate(STMP),bariummetaboratemonohydrate(Busan)andemulsionsolids2

Pounds 0.5 1.0

Primepaint Pounds 2.4 2.4Water Pounds 1,365 1,734Total(wetweight) Pounds 3,089 3,886Finisheddensity(with1.7%MC) Pounds 2,027 2,578Finalmoisturecontent(MC) % 1.7% 1.7%

1 Post-consumer gypsum includes GMGP on-site construction off-cuts and recovered gypsum material collected from demolition sites. 2 LCI data are rolled up for confidentiality reasons.



4 Declared Unit & System Boundary The declared unit is the basic reference flow set by the glass mat gypsum panels PCR for the assessed product [1]. The declared unit for this study is defined as 1MSF of GMGPs with a nominal finished thickness of ½" and 5/8". A declared unit is defined for EPDs covering the cradle-to-gate production stage which consists of three alpha-numeric modules: A1 Raw material supply; A2 Transport to the manufacturer; and A3 Manufacturing. For this EPD project report, the boundary is “cradle-to-gate” or the production stage, which includes extraction of raw material supply (cradle) through the manufacture of GMGPs ready for shipment at a distribution terminal (gate). Construction, use and end-of-life stages are excluded from the system boundary. Figure 2 shows the product stage system boundary for the declared product system. The Product Stage includes the following processes [1]:

Ø Extraction and processing of raw materials, including fuels used in product production; Ø Average and/or specific transportation of raw materials from the extraction site or source

to manufacturing site, inclusive of empty backhauls (where applicable); Ø Manufacturing of GMGPs; Ø Product packaging with product ready for shipment to distribution points or customers; Ø Average or specific transportation from manufacturing site to recycling/reuse/landfill for

pre-consumer wastes and unutilized by-products from manufacturing, including empty backhauls; and

Ø Final disposition of pre-consumer wastes inclusive of transportation.

The Product Stage excludes the following processes [1]: Ø Capital goods and infrastructure; Ø Personnel related activities (travel, office operations and supplies); Ø Energy and water use related to company management and sales activities that may be

located either within the factory site or at another location.



Figure 2: Product Stage (Module A1 to A3) System Boundary

5 Life Cycle Inventory

5.1 Data Collection and Representativeness Data collection was based on an initial survey of all GA member facility operations. GA members operate 31 facilities in the USA and Canada producing various GMGP products. Some facilities are 100% dedicated to the production of GMGP while others may produce both GMGP and paper faced gypsum boards. In total 11 facilities operated by the 7 GA company members (American Gypsum Company LLC; CertainTeed Gypsum, Inc.; CertainTeed Gypsum Canada, Inc.; Continental Building Products Operating Company, LLC; Georgia-Pacific Gypsum LLC; National Gypsum Company; PABCO® Gypsum, a division of PABCO® building products, LLC; United States Gypsum Company and CGC Inc.) completed LCI data collection questionnaires representing 35% of all GA member facilities producing GMGP. To ensure representativeness, the GMGP manufacturing plant sample also considered the scale of operations including a mix of small, medium and large GMGP production volume facilities, their



geographical location in each US census region and their source of gypsum – adjacent quarry, mine, imported gypsum ore and their use of FGD synthetic gypsum. All LCI data were averaged on the annual production basis across facilities. Overall the data is representative according to the following temporal, geographical and technological criteria:

Ø Temporal: Manufacturing process inputs and outputs were obtained for the latest 12 month period (2014 calendar year);

Ø Geographical: geographically the data represents both USA and Canadian operations across all processes; and

Ø Technological: Data represents the up-to-date technology in use in Canada and USA. All manufacturer specific data is less than two years old. All generic data is less than 10 years old.

5.2 LCI Data Sources and Data Quality This section provides a description of the primary and secondary data sources used to complete the LCA study. Data quality requirements, as specified in ASTM PCR for glass mat gypsum panels, Section 7.3, were observed [1]. This section also describes the achieved data quality relative to the ISO 14044:2006 requirements [3]. Data quality is judged on the basis of its precision (measured, calculated or estimated), completeness (e.g., unreported emissions), consistency (degree of uniformity of the methodology applied within a study serving as a data source) and representativeness (geographical, temporal, and technological). Precision: The GA participating member companies through measurement and calculation collected primary data on their production of GMGPs. For accuracy the LCA team individually validated these plant gate-to-gate input and output data. Completeness: All relevant, specific processes, including inputs (raw materials, energy and ancillary materials) and outputs (emissions and production volume) were considered and modeled to provide an industry average for GMGPs with a thickness of ½” and 5/8”. The relevant background materials and processes were taken from the US LCI Database (adjusted for known data placeholders known as “dummy”3), ecoinvent v 3.1 LCI database for US and Canada and modeled in SimaPro software v.8.1.0.60, April 2016. Consistency: To ensure consistency, the LCI modeling of the production weighted input and output LCI data for the GMGPs used the same modeling structure across the selected GA member facilities, which consisted of input raw and ancillary material, energy flows, water

3 “Dummy” is a term used by US LCI database that refers to “empty” LCI data sets (technosphere processes).



resource inputs, product outputs, emissions to air, water and soil, and material recycling and pre-consumer solid and liquid waste treatment. Crosschecks concerning the plausibility of mass and energy flows were continuously conducted. The LCA team conducted mass and energy balances at the plant and selected process level to maintain a high level of consistency. Reproducibility: Internal reproducibility is possible since the data and the models are stored and available in GA Athena GMGP LCI database developed in SimaPro, 2016. A high level of transparency is provided throughout the report as the weighted average LCI profile is presented for each of the declared products. Key primary (manufacturer specific) and secondary (generic) LCI data sources are summarized in Table 2. The provision of more detailed data to allow full external reproducibility was not possible due to reasons of confidentiality. Representativeness: The data are representative according to temporal, geographical, and technological requirements as per the ASTM PCR for glass mat gypsum panels, Section 7.1. The representativeness of the data is summarized as follows. § Time related coverage:

- GMGPs manufacturing process- primary collected data from 11 facilities: reference year 2013 (12 months); - In-bound/ out-bound transportation data- primary collected data from 11 facilities: reference year 2013 (12 months); - Natural gypsum ore – primary collected data from six quarries and one gypsum ore underground mine: reference year 2010 (12 months); the upstream natural gypsum ore profiles were updated with the most recent U.S., Canada and Spain electricity grid data; the activity data for the natural gypsum ore extraction process are deemed timely robust and no material changes are expected in the quarry/mine operations. - Generic data: the most appropriate LCI datasets were used as found in the US LCI (adjusted) Database, ecoinvent v.3.1 database for US, Canada and global, 2014.

§ Geographical coverage: the geographical coverage is the U.S. and Canada. § Technological coverage: typical or average. Generic data is publically available and may be average or specific. Table 2 provides details of the source and quality of the LCI datasets used for purposes of completing this LCA study.

Table2:SummaryofDataSourcesandQuality[SimaProv.8.1.0.60,April2016]

LCIdatasetsSourceofLCIDatabase1)2)

Comments

“Gate-to-gate”GMGPmanufacturingLCIdata GypsumAssociationPrimarydatacollectedfrom11GAmemberfacilities,referenceyear2013-A3module-Manufacturing

Inbound/outboundtransportationdata(one-way)

GypsumAssociation

Primarydatacollectedfrom11GAmemberfacilities,referenceyear2013-A2module-Transportation.



LCIdatasets(Table2continued)

SourceofLCIDatabase1)2)

Comments

NaturalgypsumoreLCIdata GypsumAssociationPrimarydatacollectedfrom7GAsitesin2010[11],Section4.1,pgs.37-41-A1module-Rawmaterialsupply.

Syntheticgypsum-FGD Ecoinvent3.1database

LCIdataismodeledbasedon[11],Section3.2.4,pgs.18-22-A1module-Rawmaterialsupply.Confidentialindustrydataareusedforde-wateringprocessofFGD;

Electricitygrid,fossilfuelsandtransportGMGPsmanufacturingprocess-ElectricitygridmixbyNorthAmericanElectricReliabilityCorporation(NERC)Region(asmodeled),includingtransmissionlosses

Ecoinvent3.1LCIdatasetsforNERCregionIt’susedforGMGPmanufacturingprocess

Electricity,mediumvoltage{ASCC}|marketfor|AllocRec,U 0%

Electricity,mediumvoltage{FRCC}|marketfor|AllocRec,U 0%

Electricity,mediumvoltage{HICC}|marketfor|AllocRec,U 0%

Electricity,mediumvoltage{MRO}|marketfor|AllocRec,U 3.9%

Electricity,mediumvoltage{NPCC}|marketfor|AllocRecU 0.7%

Electricity,mediumvoltage{RFC}|marketfor|AllocRec,U 2.3%

Electricity,mediumvoltage{SERC}|marketfor|AllocRec,U 36.4%

Electricity,mediumvoltage{SPP}|marketfor|AllocRec,U 0%

Electricity,mediumvoltage{TRE}|marketfor|AllocRec,U 49.4%

Electricity,mediumvoltage{WECC}|marketfor|AllocRec,U 7.3%

Total 100.0%

Electricity,mediumvoltage{US}|marketfor|AllocRec,includingtransmissionlosses

Ecoinvent3.1databaseIt’susedforallupstreamanddownstreamLCIdatasetsforthisproject(USadjusted}LCIdatasets

Electricity,mediumvoltage{ASCC}|marketfor|AllocRec,U 0.2%

Electricity,mediumvoltage{FRCC}|marketfor|AllocRec,U 5.2%

Electricity,mediumvoltage{HICC}|marketfor|AllocRec,U 0.3%

Electricity,mediumvoltage{MRO}|marketfor|AllocRec,U 5.6%

Electricity,mediumvoltage{NPCC}|marketfor|AllocRecU 6.5%

Electricity,mediumvoltage{RFC}|marketfor|AllocRec,U 23.0%

Electricity,mediumvoltage{SERC}|marketfor|AllocRec,U 26.9%

Electricity,mediumvoltage{SPP}|marketfor|AllocRec,U 5.2%

Electricity,mediumvoltage{TRE}|marketfor|AllocRec,U 8.5%

Electricity,mediumvoltage{WECC}|marketfor|AllocRec,U 18.5%

Total 100.0%



LCIdatasets(Table2continued)

SourceofLCIDatabase1)2)

Comments

Electricity,mediumvoltage{CA}|marketfor|AllocRec,U

Ecoinvent3.1databaseIt’susedinCanadianminedgypsumLCIprofile

Electricity,mediumvoltage{ES}|marketfor|AllocRec,U

Ecoinvent3.1databaseIt’susedinoffshorequarriedgypsumLCIprofile-Spain

Naturalgas,combustedinindustrialboiler,US USLCIDatabase It’susedinA3module-Manufacturing

Diesel,combustedinindustrialequipment/US USLCIDatabase It’susedinA3module-Manufacturing

Gasoline,combustedinequipment/US USLCIDatabase It’susedinA3module-ManufacturingLiquefiedpetroleumgas,combustedinindustrialboiler/US

USLCIDatabase It’susedinA3module-Manufacturing

Transport,combinationtruck,averagefuelmix,US

USLCIDatabaseIt’susedinA2module-Roadtransportation

Transport,singleunittruck,dieselpowered,US

USLCIDatabaseIt’susedinA2module-Roadtransportation

Transport,train,dieselpowered,US USLCIDatabase It’susedinA2module-Railtransportation

Transport,barge,averagefuelmix,US USLCIDatabaseIt’susedinA2module-Watertransportation

Transport,freight,sea,transoceanicship{GLO}|marketfor|AllocRec,U

Ecoinvent3.1databaseIt’susedinA2module-Watertransportation

Conveyor Ecoinvent3.1databaseIt’susedinA2module-Conveyortransportation;ElectricityfactorisbasedonU.S.confidentialindustrydata.

GMGPsmanufacturing–Othermaterials,chemicals3)andprocesses

Glassfiber{USadjusted}production Ecoinvent3.1databaseIt’susedinA1module-Rawmaterialsupply

Dryandwetadditives{USadjusted}production

USLCIDatabaseEcoinvent3.1database

It’susedinA1module-Rawmaterialsupply.BasedontheMaterialSafetyDataSheet(MSDSs)providedconfidentiallybyGAplants.

Packagingmaterial{USadjusted}productionUSLCIDatabase

Ecoinvent3.1database

It’susedinA1module-Rawmaterialsupply.Forfewselectedpackagingmaterial(suchasink,edgeglue),MSDSasprovidedbyGAplantswereused.

Lubes{USadjusted}production Ecoinvent3.1databaseIt’susedinA1module-Rawmaterialsupply

Pre-consumerwaste{USadjusted}disposal Ecoinvent3.1database It’susedinA3module-ManufacturingNotes:1)LCAisconductedwithSimaProLCASoftwarev.8.1.0.60,April2016.2)USLCIdatabase“dummies”(emptyLCIdatasets)aresubstitutedwithecoinventv3.1LCIdatabaseproxies.3)AllapplicableMSDSforusedchemicalcompoundswerecollectedandanalyzedfromparticipatingGAplants.



5.3 Cut-off Criteria and Allocation Rules The cut-off requirements as per the ASTM PCR for glass mat gypsum panels, Section 7.2, were followed [1]. All input/output flow data reported by the participating GA member facilities were included in the LCI modelling. None of the reported flow data were excluded based on the cut-off criteria. Allocation procedures observed the requirements and guidance of ISO 14044:2006, clause 4.3 and those specified in ASTM PCR for glass mat gypsum panels, Section 7.5 [1]. The majority of the GA facility operations produce other products besides GMGPs as well as other GMGP products other than thickness of ½” and 5/8” for exterior sheathing applications and as such allocation was necessary. As a result, plant specific generic formulations for 1 MSF of the two products of interest were used to model and calculate the required input raw (both primary and secondary) and ancillary materials. “Mass” was deemed as the most appropriate physical parameter for allocation used for the GMGPs system (between ½” and 5/8” GMGPs and other types of calcined co-products) to estimate the input energy flows (electricity, natural gas, propane, etc.), water input, process emissions and waste flows. ISO requirements and recommendations were followed in this LCA study for allocation procedures in general (Clause 4.3.4.2) and allocation procedures for reuse and recycling (Clause 4.3.4.3). For upstream raw materials (e.g., natural quarried gypsum, flue gas desulfurized gypsum) the study drew on a previous ISO 14044/44 conformance 2011 LCA report prepared for the Gypsum Association [11], Section 3.2.4, pg. 17-23. Where warranted these upstream raw material profiles were updated for this study (most recent electricity grid was applied for U.S., Canada and Spain-see Table 5), but the allocation methods used previously were retained. “Mass” was also deemed as the most appropriate physical parameter for allocation of the total environmental load of the quarry system between the main product and co-products. However, for synthetic FGD gypsum a system expansion methodology was used whereby the GMGP product system is debited for intermittent treatment of FGD (de-watering, transportation) and credited for avoided landfilling of FGD-see Section 3.2.4 for details [11]. Results of the sensitivity analysis on the allocation rules (system expansion vs cut-off criteria) are presented in section 7. According to the cut-off criteria, recycled and recovered materials can be considered raw materials. Only the materials, water, energy, emissions, and other elemental flows associated with reprocessing, handling, sorting, and transportation from the generating industrial process to their use in the production process need to be considered. Any allocations before reprocessing shall be allocated to the original product [1]. In addition, the following allocation rules are applied- see Section 7.5 [1]:

- Allocation related to transport is based on the mass and distance of transported raw material inputs and waste outputs;

- The environmental flows related to the disposal of the manufacturing (pre-consumer) solid and liquid waste are allocated to module A3 Manufacturing.



5.4 Environmental Category Indicators The ASTM PCR for glass mat gypsum panels, Section 8.0, sets out the environmental category indicators, characterization methods, resource use and waste generated measures to be supported by the LCA [1]. This section lists the LCIA category indicators (Table 3) and resource use and waste generated parameters supported in this LCA study (Table 4).

Table3:LCIACategoryIndicators

Impactcategory CategoryindicatorUnit(perDeclaredUnit)

Sourceofthecharacterizationmethod

Levelofsitespecificityselected

Environ-mentalmedia

Climatechange Globalwarmingpotential(GWP) kgCO2–equiv.

TRACI2.1,July2012/IPCC2007 Global Air

OzonedepletionDepletionpotentialofthestratosphericozonelayer(ODP)

kgCFC-11equiv. TRACI2.1,July2012/WMO:2003 Global Air

Acidification Acidificationpotential(AP) kgSO2equiv. TRACI2.1,July2012 North

America Air,Water

Eutrophication Eutrophicationpotential(EP) kgNequiv. TRACI2.1,July2012 North

America Air,Water

SmogPhotochemicalozonecreationpotential(POCP)

kgO3equiv. TRACI2.1,July2012 NorthAmerica Air

Furthermore, as specified in ASTM PCR for glass mat gypsum panels, the following mandatory resource use and waste indicators shall be reported as described in Table 4 [1].

Table4ParametersDescribingResourceUseandWasteCategories

Parameter Unit(perDeclaredUnit)

Totalprimaryenergyconsumption

Non-renewable,fossil MJ,HigherHeatingValue(HHV)

Non-renewable,nuclear MJ(HHV)

Renewable,solar,wind,hydroelectric,andgeothermal MJ(HHV)

Renewable,biomass MJ(HHV)

Materialresourcesconsumption

Non-renewablematerials kg

Renewablematerials kg



Parameter(Table4continued)

Unit(perDeclaredUnit)

Recoveredmaterials kg

Netfreshwater L

Wastegenerated

Hazardouswaste kg

Non-hazardouswaste kg

It should be noted that total primary energy includes the total energy consumed over the cradle-to gate (modules A1-A3) in delivering the declared unit (including pre-consumer waste treatment). In addition, “recovered materials” indicator (including pre-consumer- FGD synthetic gypsum, post-consumer gypsum) is reported under “material resources consumption”. According to the ASTM PCR for glass mat gypsum panels, “fresh water is naturally occurring water on the earth’s surface and underground as groundwater in aquifers and underground streams [1]. The term specifically excludes seawater and brackish water, but does include fresh water that has been treated to make it potable. Energy use and other impacts associated with fresh water treatment are not included”. Based on the definition of the fresh water (including surface and groundwater) [12], net fresh water indicator covers the following water flows: “water, fresh”; “water, lake”; “water, river”; “water rain” and “water, well in ground”. Water flows such as “water, cooling, unspecified natural origin”; “water, turbine use, unspecified natural origin”; “water, unspecified natural origin”; “water, salt, ocean”, and “water, salt, sole” are excluded as these flows are not specified as fresh.

5.5 Product Manufacturing Life Cycle Inventory The cradle-to-gate LCA model was created in SimaPro LCA software 8.1.0.60, 2016. The weighted average model considers the three modules: A1 Raw material supply, A2 Transport and A3 Manufacturing. A separate LCI model was created for each member facility per 1 MSF of GMGPs; all facility specific LCI models were then aggregated to calculate the weighted average LCI profile for the GMGPs of interest. Facility specific average weighting factors were calculated based on each facility contribution to the overall total GMGPs manufacturing across all facilities participating in the EPD project. The weighted average LCI profile is reported in Table 5 by product thickness. Table 6 summarizes the inbound and outbound transportation by mode and distance for each product thickness. Purchased electricity and natural gas were reported to be the primary manufacturing energy inputs. While the electricity is used at all production stages most of the natural gas is used



during the drying of the natural gypsum, calcining or stucco production and drying the final board product. Diesel is used at plant for on-site equipment (not transportation). Gasoline and propane are typically used to operate the on-site mobile equipment (e.g. forklifts, small engine vehicles) within the facility. Gate-to-gate emissions to air were measured and reported at the stack after the utilization of environmental equipment (see Section 8, last paragraph). Total suspended solids (TSS) were the only emissions to water reported by the surveyed facilities. There were no emissions to land reported by the reporting facilities.

Table5:Inputs/Outputs–1MSFofGMGPsbyThickness(A3Manufacturing)

Inputs/Outputs Units 1MSF-½”GMGP 1MSF-5/8”GMGP

1.MaterialInputs

GypsummaterialandglassmattingMinednaturalgypsumore(domesticUSsourceandimportedfromCanada4) Pounds 245 307

Quarriednaturalgypsumore(domesticUSsourceandimportedfromSpain5) Pounds 1195 1509

Pre-consumergypsum-FGDsyntheticgypsum Pounds 205 275

Post-consumergypsum(recoveredgypsumfromconstruction/demolitionsites)

Pounds 19.1 23.6

Glassmatting Pounds 99.0 99.0


Starch Pounds 0.4 0.4

Fiberglass(otherthanmattingabove) Pounds 2.8 4.2

Dispersant Pounds 2.6 2.8

Retarder Pounds 0.3 0.3

Potassiumsulfate Pounds 2.2 2.3

Dextrose Pounds 0.01 0.00

Boricacid Pounds 0.09 0.16

Landplaster Pounds 1.2 1.5

Foamingagent(soap) Pounds 0.4 0.4

BMaccelerator Pounds 2.6 2.6

4 Canadian mined natural gypsum ore is used by less than three facilities; LCI data are rolled up for confidentiality reasons. 5 Quarried natural gypsum ore (imported from Spain) is used by less than three facilities; LCI data are rolled up for confidentiality reasons.



Inputs/Outputs(Table5continued)

Units 1MSF-½”GMGP 1MSF-5/8”GMGP

Edgepaste Pounds 2.2 2.3

Flyash Pounds 0.6 0.6

Siliconeproducts Pounds 8.8 9.8

Biocide,sodiumomadine,sodiumtrimetaphosphate(STMP),bariummetaboratemonohydrate(Busan)andemulsionsolids6

Pounds 0.5 1.0

Wax Pounds 0.8 0.9

Primepaint Pounds 2.4 2.4

Packagingmaterial

Paperendtape Pounds 0.22 0.30

Ink(waterbased) Pounds 0.001 0.001

Ink(oilbased) Pounds 0.002 0.002

Ink(alcoholbased) Pounds 0.10 0.12

Shrink-wrap Pounds 0.06 0.08

Plasticslipsheets Pounds 0.54 0.68

Railbags Pounds 1.01 1.27

Otherplastics Pounds 0.12 0.16

Cardboardedgeprotectors Pounds 0.11 0.13

Plasticbanding Pounds 0.01 0.01

Ziptape Pounds 0.15 0.20

Dunnage/Bunks/Sleutters(DBS)(usedoverandover) Pounds 41.3 52.7

AdhesiveforDBS Pounds 0.13 0.16

Lubes

MotorOils Pounds 0.009 0.012

GearOil(Transmission) Pounds 0.013 0.016

Lubricants Pounds 0.024 0.031

HydraulicFluid Pounds 0.214 0.269

Greases Pounds 0.005 0.006

6 LCI data are rolled up for confidentiality reasons.





Antifreeze Pounds 0.005 0.006

2.EnergyInputs

Electricity kWh 60.3 76.9

Naturalgas CubicFeet 1,610.2 2,056.9

Dieselfueloil Gallons 0.08 0.10

Propane Pounds 0.12 0.15

Gasoline Gallons 0.00018 0.00023

3.WaterConsumption

Water(inproductformulation)(97.5%freshwater;2.5%reclaimedwater)density=8.345lbs/gal(U.S.)

Pounds 1,365 1,734

4.ProductandBy-productOutputs

Referenceflow SquareFeet 1,000 1,000

Totalfinalweight-(Conversionto1kg)

Pounds (ft2/kg)

2,027(1.09)

2,578(0.86)

Off-specGWBusedasBDS Pounds 6.8 8.9

5.Emissionstoair(non-combustion)

ParticulateMatter(PM)>10microns Pounds 0.31 0.382.5microns<PM<10microns Pounds 0.03 0.04PM<2.5microns Pounds 0.15 0.18Lead(Pb) Pounds 1.8E-06 2.4E-06Mercury(Hg) Pounds 1.6E-05 2.1E-05

VOC Pounds 0.20 0.26

6.Emissionstowater

Totalsuspendedsolids(TSS) Pounds 3.9E-04 5.0E-04

7.SolidWaste

Non-hazardoussolidwastetolandfill Pounds 22.8 29.2

Other(s)non-hazardoussolidwaste(forreclamation,agriculturaluse) Pounds 2.96 3.8

Hazardoussolidwastetoincinerator Pounds 6.9E-07 9.1E-07

Papertorecycler Pounds 0.03 0.04

Plastictorecycler Pounds 0.0003 0.0004

Woodtorecycler Pounds 0.0005 0.0007





Steelscraptorecycler Pounds 0.04 0.05

8.Wastewaterandotherliquidwaste

Wastewatertowastetreatmentfacility Gallons 0.11 0.14

Solventmixturewastetoincinerator Gallons 5.3E-05 6.5E-05

Sludgewastetolandfill Pounds 0.036 0.045

Table6:WeightedAverageInbound/OutboundTransportationModesandDistances(one-way)

In-boundtransportation(one-way)

Truck(mi)

Rail(mi)

Ocean(mi)

Barge(mi)

Conveyor(ft.)

Truck(mi)

Rail(mi)

Ocean(mi)

Barge(mi)

Conveyor(ft.)

1MSF-½”GMGP 1MSF-5/8”GMGP

Gypsummaterialandglassmatting

48 0 1,053 3.3 449 50 0 1,365 4.4 449


8.5 0.2 2.9 0 0 9.5 0.2 3.1 0 0

Packagingmaterial

0.69 0 0 0 8.1 0.88 0 0 0 8.1

Lubes 0.035 0 0 0 0 0.044 0 0 0 0

Out-boundtransportation(one-way)

8.2E-03 1.4E-03 0 0 0 1.1E-02 1.7E-03 0 0 0



6 Life Cycle Impact Assessment This section summarizes the product stage life cycle impact assessment (LCIA) results including resource use and waste generated metrics based on the cradle-to-gate life cycle inventory inputs and outputs analysis. The results are calculated on the basis of one thousand square feet of GMGP with a nominal thickness of ½” and 5/8” (Table 7).

Table7:ProductStage(A1-A3)-EPDResults–1MSFof½”and5/8”GMGP

CategoryIndicator Unit 1MSF½”GMGP

1MSF5/8”GMGP

Globalwarmingpotential,GWP kgCO2equiv. 358 417

Ozonedepletionpotential,ODP kgCFC-11equiv. 5.8E-05 6.6E-05

Acidificationpotential,AP kgSO2equiv. 2.8 3.4

Eutrophicationpotential,EP kgNequiv. 0.51 0.58

Smogcreationpotential,POCP kgO3equiv. 35.1 42.0

TotalprimaryenergyconsumptionNon-renewable,fossil,PENR-fossil MJ,HHV 5,483 6,441

Non-renewable,nuclear,PENR-nuclear MJ,HHV 433 483Renewable, solar, wind, hydroelectric, andgeothermal,PER-SWHG

MJ,HHV 90 99

Renewable,biomass,PER-biomass MJ,HHV 89 94MaterialresourcesconsumptionNon-renewablematerials,NRMR kg 739 912

Renewablematerials,RMR kg 2.1 2.4

Recoveredmaterials,RM kg 102 135

Netfreshwaterconsumption,NFW L 1,705 1,952WastegeneratedHazardouswaste,HW kg 0.27 0.28

Non-hazardouswaste,NHW kg 17.5 20.9

In addition, the GMGPs production results are delineated by information module (A1 – Raw material supply; A2 – Raw material transport; and A3 – GMGP manufacturing). Figures 3 and 4 provide a percent contribution summary by information module for each of the selected LCIA indicators and LCI parameters for ½” and 5/8” GMGPs, respectively. Contribution analysis is an analytical method used to support the interpretation of LCA results and to facilitate the reader's understanding of the environmental profile of the declared product. Tables 8 and 9 provide an absolute and percent contribution summary by main input/output technosphere flows for each of the selected LCIA indicators for ½” and 5/8” GMGPs, respectively.



Figure 3: EPD Results by Information Module – 1 MSF of ½” GMGP – % Basis

Figure 4: EPD Results by Information Module – 1 MSF of 5/8” GMGP – % Basis



Table8:ContributionAnalysis–1MSFof½”GMGPProductSystem–Absoluteand%Basis

CategoryIndicator

RawMaterialSupply-A1Transport-

A2

Manufacturing-A3

TotalGypsum Additives

&lubesGlassmat Packaging On-siteenergy

consumptionWastedisposal

AbsoluteBasisper1MSFof1/2”GMGP

GWP,kgCO2eq. 3.9 25.5 131.6 1.5 36.2 159.5 0.1 358

ODP,kgCFC-11eq. 1.6E-07 2.9E-05 1.5E-05 6.2E-08 2.4E-09 1.4E-05 6.1E-09 5.8E-05

AP,kgSO2eq. 0.05 0.1 0.8 0.03 0.6 1.2 2.5E-04 2.8

EP,kgNeq. 0.004 0.1 0.2 0.002 0.03 0.1 2.9E-03 0.51

POCP,kgO3eq. 0.80 1.7 9.5 0.08 18.4 4.7 6.6E-03 35.1

PercentBasisper1MSFof1/2”GMGP

GWP,kgCO2eq. 1% 7% 37% 0.4% 10% 45% 0.03% 100%

ODP,kgCFC-11eq. 0.3% 49% 26% 0.1% 0% 24% 0.01% 100%

AP,kgSO2eq. 2% 5% 29% 0.9% 22% 42% 0.01% 100%

EP,kgNeq. 1% 21% 43% 0.4% 7% 28% 0.58% 100%

POCP,kgO3eq. 2% 5% 27% 0.2% 52% 13% 0.02% 100%

Table9:ContributionAnalysis–1MSFof5/8”GMGPProductSystem–Absoluteand%Basis

CategoryIndicator


A2

Manufacturing-A3

Total

Gypsum Additives&lubes

Glassmat Packaging On-siteenergy


AbsoluteBasisper1MSFof5/8”GMGP

GWP,kgCO2eq. 4.6 29.9 131.6 1.9 45.0 203.5 0.1 417

ODP,kgCFC-11eq. 2.0E-07 3.2E-05 1.5E-05 7.9E-08 3.0E-09 1.8E-05 7.8E-09 6.6E-05

AP,kgSO2eq. 0.06 0.2 0.8 0.03 0.8 1.5 3.1E-04 3.4

EP,kgNeq. 0.005 0.1 0.2 0.003 0.04 0.2 3.7E-03 0.58

POCP,kgO3eq. 0.95 1.9 9.5 0.10 23.6 6.0 8.5E-03 42.0



CategoryIndicator(Table9continued)


A2

Manufacturing-A3

Total

Gypsum Additives&lubes

Glassmat Packaging On-siteenergy


PercentBasisper1MSFof5/8”GMGP

GWP,kgCO2eq. 1% 7% 32% 0.5% 11% 49% 0.04% 100%

ODP,kgCFC-11eq. 0.3% 48% 23% 0.1% 0% 28% 0.01% 100%

AP,kgSO2eq. 2% 5% 24% 1.0% 24% 45% 0.01% 100%

EP,kgNeq. 1% 22% 37% 0.4% 8% 31% 0.6% 100%

POCP,kgO3eq. 2% 5% 23% 0.2% 56% 14% 0.02% 100%

7 Interpretation The cradle-to-gate manufacture of 1 MSF of ½” and 5/8” GMGP embodies about 6.1 GJ and 7.1 GJ of primary energy use and emits in the order of 358 kg and 417 kg of greenhouse gases, respectively. For both panel thicknesses, over 90% of the total primary energy is derived from non-renewable fossil fuels. On-site energy use at the plant and the fiberglass mat input were the major contributing sources to total primary use. Across the three production information modules, Module A1 Raw Material Supply generally contributes the largest share of the LCIA category results – accounting for between 30% (smog) and 76% (ozone depletion) of the impact burden. Much of the burden can be traced to fiberglass matt and additive inputs used in the panel product (see Tables 8 and 9). The application of pre-consumer- FGD synthetic gypsum and post-consumer gypsum material in the manufacturing process is beneficial for the gypsum industry as it reduces the dependency on non-renewable material resources (natural gypsum ore). With the exception of acidification and smog potential impacts, Module A2 Transportation is generally a minor contributor (<10%) to the overall impact of GMGPs. Module A3 Manufacturing is responsible for a significant share of total energy use (50%) and is generally the largest source of greenhouse gas emissions (over 45%), acidification potential (over 42 %) and non-renewable energy, fossil (48%). Plant energy use, specifically natural gas and electricity use, are the largest contributors to the manufacturing burdens. As part of the interpretation phase, a sensitivity analysis on allocation rules, base case (system expansion) vs. altered assumption (cut-off criteria), was conducted- see also section 5.3. The procedure of sensitivity analysis is a comparison of the results obtained using base case allocation rules with the results obtained using altered allocation rules. Sensitivity can be expressed as the percentage of change or as the absolute deviation of the results. On this basis, significant changes in the results (e.g., larger than 10%) can be identified.



Tables 10 and 11 show the sensitivity of EPD results with respect to the allocation rules for ½” and 5/8” GMGPs, respectively. EPD results were found to be less sensitive to a variation of the allocation rules. The application of “cut-off” vs “system expansion” allocation rule affect EPD results insignificantly, less than 1.5% across all EPD indicators, with the exception of smog (around 2.5%), for ½” and 5/8” GMGPs, respectively.

Table10:SensitivityAnalysis–EPDresults,1MSFof½”GMGPProductSystem-Absoluteand%basis

CategoryIndicatorBasecase-

Allocationbysystemexpansion

Alteredassumption-Allocationby"cut-

off"rules

Deviation-inabsolutebasis

Deviation-in%

GWP(kgCO2eq.) 358 363 4 1.2%ODP(kgCFC-11eq.) 5.8E-05 5.8E-05 5.9E-08 0.1%AP(kgSO2eq.) 2.8 2.9 0.028 1.0%EP(kgNeq.) 0.51 0.51 0.002 0.3%POCP(kgO3eq.) 35.1 35.9 0.8 2.3%PENR-fossil(MJ) 5483 5542 58.9 1.1%PENR-nuclear(MJ) 433 434 0.5 0.1%PER-SWHG(MJ) 90 90 7.2E-03 0%PER-biomass(MJ) 89 89 1.8E-03 0%NRMR(kg) 739 739 1.3E-04 0%RMR(kg) 2.1 2.1 9.9E-05 0%RM(kg) 102 102 0 0%NFW(L) 1705 1705 0 0%HW(kg) 0.27 0.27 0 0%NHW(kg) 17.5 17.5 0 0%

Table11:SensitivityAnalysis–EPDresults,1MSFof5/8”GMGPProductSystem-Absoluteand%basis

CategoryIndicatorBasecase-

Allocationbysystemexpansion


off"rules


Deviation-in%

GWP(kgCO2eq.) 417 423 6 1.4%ODP(kgCFC-11eq.) 6.6E-05 6.6E-05 7.9E-08 0.1%AP(kgSO2eq.) 3.4 3.4 0.0 1.1%EP(kgNeq.) 0.58 0.58 0.00 0.4%POCP(kgO3eq.) 42.0 43.1 1.1 2.5%PENR-fossil(MJ) 6441 6520 79.1 1.2%PENR-nuclear(MJ) 483 484 0.7 0.1%PER-SWHG(MJ) 99 99 9.2E-03 0%PER-biomass(MJ) 94 94 2.4E-03 0%NRMR(kg) 912 912 1.7E-04 0%RMR(kg) 2.4 2.4 1.3E-04 0%



CategoryIndicator(Table11continued)

Basecase-Allocationby

systemexpansion


off"rules


Deviation-in%

CategoryIndicator Basecase-Allocationby

systemexpansion


off"rules


Deviation-in%RM(kg) 135 135 0 0%NFW(L) 1952 1952 0 0%HW(kg) 0.28 0.28 0 0%NHW(kg) 20.9 20.9 0 0% To summarize, the significance of the EPD results is as follows:

Ø As raw material supply is a substantial contributor to the overall burden of the two GMGP products, any process improvements that either reduce the quantity of glass matting and additives used or the possible substitution of lower impact materials in place of these two inputs, while retaining the panel’s performance properties, would markedly improve the product’s environmental footprint.

Ø As the manufacturing stage is also a substantial consumer of energy and responsible for a large share of the impacts, any process or energy conservation improvements would also directly and significantly lower the environmental profile of GMGPs.

Ø The transport of raw materials, while generally the least burdensome activity stage, contributes significantly to the acidification and smog potential impacts, so steps taken to source inputs in closer proximity to the manufacturing plant would also yield an improved environmental footprint.

8 Additional Environmental Information • Health Protection Manufacture

The OSHA standards are applicable and followed. - U.S. Department of Labor, Occupational Safety & Health Administration (OSHA), 29 CFR, PART 1910 Occupational Safety and Health Standards. (https://www.osha.gov/pls/oshaweb/owasrch.search_form?p_doc_type=STANDARDS&p_toc_level=1&p_keyvalue=1910 ) No additional health protection measures extending beyond mandatory occupational safety measures for commercial operations are required.

• Environmental Protection Manufacture and Equipment The GA member manufacturing facilities comply with the regional (US and Canadian) environmental protection requirements, monitor and report the emissions to air during the manufacturing process as per the following: - EPCRA Section 313 Toxic Release Inventory Reporting (U.S.) (http://www.ecy.wa.gov/epcra/section313.html ) - The Canadian National Pollutant Release Inventory (NPRI) reporting (http://www.ec.gc.ca/inrp-npri/default.asp?lang=En&n=4A577BB9-1 )



Environmental equipment typically used in the GMGPs manufacturing facilities are as follows: fabric filter – high temperature (baghouse), fabric filter- low temperature (baghouse), bin vent filter, drum filter, dry filter, cartridge filter, precipitator and water sprinkler for dust control.

9 Declaration Type and Product Average Declaration The type of EPD based on this EPD project report is defined as: - A “Cradle-to-gate” EPD of GMGPs covering the product stage (modules A1 to A3) and is intended for use in Business-to-Business communication. GA EPD of glass mat gypsum panels UNSPSC Code 30161500 falls under the description: - An average product EPD, as an average from several GA manufacturers’ facilities (in this case, GA member manufacturers as listed under “GA Member Companies Corporate Locations”, see pg. III-IV). - GA EPD represents an average performance for the GMGPs with a nominal finished thickness of ½” and 5/8”.

10 Declaration Comparability Limitation Statement The following ISO statement indicates the EPD comparability limitations and intent to avoid any market distortions or misinterpretation of EPDs based on the ASTM PCR for glass mat gypsum panels:

- EPDs from different programs (using different PCR) may not be comparable. - Declarations based on the ASTM PCR for glass mat gypsum panels are not comparative assertions; that is, no claim of environmental superiority may be inferred or implied.

11 EPD Explanatory Material For any explanatory material, in regard to the GA GMGPs EPD based on this EPD project report, please contact the program operator. ASTM International Environmental Product Declarations 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959, http://www.astm.org



12 References 1. ASTM International, Product Category Rules For Preparing an Environmental Product

Declaration For Glass Mat Gypsum Panels, August 2016. 2. ISO 14040: 2006 Environmental management - Life cycle assessment - Principles and

framework. 3. ISO 14044: 2006 Environmental management - Life cycle assessment - Requirements and

guidelines. 4. ISO 14021:1999 Environmental labels and declarations -- Self-declared environmental

claims (Type II environmental labelling). 5. ISO 14025: 2006 Environmental labeling and declarations - Type III environmental

declarations - Principles and procedures. 6. ISO 21930: 2007 Building construction – Sustainability in building construction –

Environmental declaration of building products. 7. EN 15804:2012, Sustainability of construction works- Environmental product declarations-

Core rules for the product category of construction products. 8. ASTM Program Operator for Product Category Rules (PCRs) and Environmental Product

Declarations (EPDs), General Program Instructions, Version 7.0, 14/06/2016. 9. ASTM C1177 Standard Specification for Glass Mat Gypsum Substrate for Use as

Sheathing. 10. ASTM C1658 Standard Specification for Glass Mat Gypsum Panels. 11. A Cradle-to-Gate Life Cycle Assessment of ½” Regular and 5/8” Type X Gypsum Wallboard.

Prepared by the Athena Sustainable Materials Institute, December 2011, http://www.pharosproject.net/uploads/files/sources/1238/1337635897.pdf, Section 4.1, pgs. 37-41.

12. ISO 14046:2014 Environmental management - Water footprint - Principles, requirements and guidelines.

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