CertainTeed Fence, Railing and Decking...CertainTeed Fence, Rail and Deck Life Cycle Assessment 1...

Life Cycle Assessment Report

Cer ta inTeed

Fence, Railing and Decking

CertainTeed Fence, Rail and Deck Life Cycle Assessment

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This life cycle assessment (LCA) was conducted for vinyl rail, vinyl fence and composite rail products manufactured by CertainTeed Fence, Rail and Deck. The product lines for this study include: Bufftech (vinyl fence), Kingston (vinyl rail) and Panorama (composite rail). Cradle-to-grave impacts are reported per eight feet and illustrate a range of possible impacts. This work was performed by Sustainable Solutions Corporation for CertainTeed. The objective of CertainTeed in commissioning this study was to quantify and understand the environmental impacts throughout the life cycle of the products; as a tool in the product design process of the products; and as an input to the BEES (Building for Environmental and Economic Sustainability) life cycle product database. The data was submitted to NIST for publication in October 2014 and will be found in the database which can be located at http://ws680.nist.gov/Bees.

LCA is a rigorous study of the inputs and outputs of a particular product which provides a scientific basis for evaluating the impacts throughout the life cycle. LCA is an alternative to the single-criterion decision-making that currently guides many environmental choices. It enables a deeper understanding of the environmental footprint, which benefits manufacturers in improving their product’s environmental performance and their manufacturing processes, as well as enables consumers to make decisions on products and materials in regard to the associated impacts of the particular product.

Goals

The goals of this study were to:

• Provide a baseline LCA in order to understand and evaluate the impacts of the Vinyl Fence, Vinyl Rail and Composite Rail across the product life cycle.

• As a basis for publication in the BEES product database.

• Position CertainTeed Fence, Rail and Deck as an industry leader in product stewardship.

• Prepare CertainTeed for sustainable supply chain requirements, carbon taxes, and other potential policy requirements.

• Provide competitive analysis and positioning in order to analyze and evaluate claims or LCA/EPD information published in the future by competitors.

• To meet future requirements for green purchasing programs for the United States Government, corporations, or other businesses.

Methodology

This study was conducted according to the life cycle inventory (LCI) and life cycle impact assessment (LCIA) standards established by the International Organization for Standardization (ISO) life cycle assessment standards ISO 14040 series. The geographic boundary for this study is primarily North America. This is a cradle-to-grave LCA study examining select vinyl rail, vinyl fence and composite rail products from raw materials extraction and processing through end of life.

For this life cycle assessment, Sustainable Solutions Corporation (SSC) collected specific data on energy and material inputs, wastes, water use, emissions, and transportation impacts for the Buffalo, NY facility. Production data was allocated for these inputs in collaboration with process experts and allocated by pound of production. The National Renewable Energy Lab (NREL) US LCI database, ecoinvent database, and literature served as the sources of secondary inventory data for energy, transportation, and raw materials processes not directly collected from CertainTeed. Cumulative energy demand and the National institute of Standards and Technology (NIST) BEES 4.04+ (Building for Environmental and Economic Sustainability) factors were the methodologies selected for the life cycle impact assessment.

Executive Summary


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Key Findings

Based on the results from the life cycle assessment, the life cycle impacts for Bufftech and Panorama impacts are driven by the installation phase; raw materials are the main driver for the Kingston railing system. The reduction in electricity impacts from the purchase of hydro-electric energy reduces the overall impacts of global warming, acidification, criteria air pollutants, ecotoxicity, smog, and natural resource depletion in the manufacturing phase for all products. The composite rail has clear advantages in raw materials as the primary ingredient is recycled content obtained from product returns of composite deck product. These factors contribute to overall decreased impacts in most impact categories for the Panorama railing systems.

Recommendations

CertainTeed should use the results of this life cycle impact assessment study for reducing impacts and product improvements including:

• Communicate results of the LCA to R&D personnel and new product development teams. Use these LCA results as a tool during the product development cycle with the intent of evaluating lower impact ingredients, suppliers, and design.

– Any way to reduce the installation materials required while maintaining product performance would be the best way to reduce environmental impacts.

• Encourage suppliers to develop life cycle inventories and implement programs to reduce their own operational environmental impacts.

• Enhance installer training to encourage more efficient product installation techniques.

• While the contract with the local hydropower facility in which CertainTeed purchases all electricity for the facility greatly reduces upstream impacts from electricity for all products, the results of this LCA can continue to evaluate energy conservation opportunities to reduce energy consumption and related impacts in the manufacturing operation.

– Sub-metering electricity can help enable conservation analysis.

• Proceed with the publication of the LCA data in the BEES database, which is maintained by NIST (National Institute for Standards and Technology).

Executive Summary (continued)


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Executive Summary ........................................................... i

List of Figures ...................................................................iv

List of Tables ......................................................................v

Introduction ...................................................................... 1

Background ....................................................................... 1

Overview of Life Cycle Assessment ................................... 2

Goal and Scope Definition ............................................. 4–7

Goal of the Study .............................................................. 4

Functional Unit .................................................................. 5

System Boundary .............................................................. 6

Cut-off Criteria .................................................................. 7

Data Sources and Modeling Software ......................... 8–13

Data Quality ....................................................................... 8

Data Sources ..................................................................... 9

Heat Stabilizer ................................................................. 13

Modeling Software .......................................................... 13

Life Cycle Inventory Analysis .................................... 14–16

Raw Materials and Product Recipe Overview .................. 14

Manufacturing Process Overview ................................... 15

Distribution ..................................................................... 16

Installation ...................................................................... 16

End-of-Life ...................................................................... 16

Life Cycle Impact Assessment (LCIA) ............................. 17

Impact Categories / Impact Assessment ......................... 17

Selected Impact Categories ............................................. 18

Manufacturing Process Allocation and Assumptions ...... 19

Initial Service and End-of-Life Assumptions ................... 19

Vinyl Fence, Vinyl Rail and Composite Rail LCA Results ..................................... 20–47

Manufacturing Impacts .............................................. 20-23

Raw Material Impacts ............................................... 24–30

Installation and Use Phase ........................................ 31–34

Overall Environmental Impact .................................. 35–47

Hydropower Sensitivity Analysis ............................... 48–51

Recycled Content Sensitivity Analysis ....................... 52–53

Limitations ...................................................................... 54

Conclusions .................................................................... 55

Table of Contents


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Figure 1.1 – The Four Stages of Life Cycle Assessment .... 2

Figure 2.1 – System Boundary for Vinyl Fence, Vinyl Rail and Composite Rail ....................... 6

Figure 6.1 – Life Cycle Stage Control Diagram ................ 20

Figure 6.2 – Energy Distribution of the Buffalo Manufacturing Process ............................. 21

Figure 6.3 – Global Warming Potential Distribution to Manufacture Vinyl Rail and Fence Products ................ 22

Figure 6.4 – Environmental Impacts (BEES Methodology) of Buffalo Production Operations (per lb Produced) ....... 23

Figure 6.5 – Relative Environmental Impacts of One lb Each of Raw Materials ......................................... 24

Figure 6.6 – Relative Environmental Impact (BEES Methodology) Distribution of Vinyl Rail/Fence Formulation .......................................... 26

Figure 6.7 – Relative Environmental Impact (BEES Methodology) Distribution of Kingston Rail Formulation ............................................... 27

Figure 6.8 – Relative Environmental Impact (BEES Methodology) Distribution of Panorama Rail Formulation ............................................. 29

Figure 6.9 – Bufftech Chesterfield Installation Materials (per 8ft section) ............................ 31

Figure 6.10 – Bufftech New Lexington Installation Materials (per 8ft section) ............................ 29

Figure 6.11 – Kingston Installation Materials (per 8ft section) .............................................................. 33

Figure 6.12 – Panorama Rail Installation Materials (per 8ft section) .............................................................. 34

Figure 6.13 – Cumulative Energy Demand (CED) for the Life Cycle Stages of CertainTeed Bufftech Fence Systems (MJ / 8ft)............... 36

Figure 6.14 – Cumulative Energy Demand (CED) for the Life Cycle Stages of Kingston and Panorama Railing Systems (MJ / 8ft) .............................................. 36

Figure 6.15 – Global Warming Potential (GWP) for the Life Cycle Stages of Bufftech Fence (g CO2 eq / 8ft product) ................................................... 37

Figure 6.16 – Global Warming Potential (GWP) for the Life Cycle Stages of CertainTeed Railing Systems (g CO2 eq / 8ft) ..................................... 38

Figure 6.17 – Environmental Impacts of Bufftech Chesterfield Vinyl Fence (BEES Impact Assessment Methodology) ....................... 40

Figure 6.18 – Environmental impacts of Bufftech New Lexington Vinyl Fence (BEES Impact Assessment Methodology) ....................... 42

Figure 6.19 – Overall Life Cycle Comparison of the New Lexington and Chesterfield Fence Lines ............ 43

Figure 6.20 – Environmental Impacts of Kingston Vinyl Railing System ........................................ 45

Figure 6.21 – Environmental Impacts of Panorama Composite Rail (BEES Impact Assessment Methodology) ....................... 47

Figure 7.1 – Sensitivity Analysis on the Electricity Generation Source for the FRD Manufacturing Process ................................ 48

Figure 7.2 – Sensitivity Analysis on the Electricity Generation Source for the Life Cycle of the Kingston Railing System ................. 50

Figure 7.3 – Sensitivity Analysis on the Electricity Generation Source for the Life Cycle of the Panorama Railing System ............... 51

Figure 7.4 – Relative Overall Life Cycle Environmental Impacts of Bufftech Chesterfield Fence with and without Recycled Content ................................. 53

List of Figures


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Table 2.1 – Bufftech® Vinyl Fence Product Details ............ 5

Table 2.2 – Kingston Vinyl Rail Product Details................. 5

Table 2.3 – System Boundary Description ........................ 6

Table 3.1 – Data Sources for Vinyl Fence, Vinyl Rail and Composite Rail ......................................... 10

Table 4.1 – Vinyl Fence (Bufftech) Product Recipe .......... 14

Table 4.2 – Vinyl Rail Product Recipe.............................. 14

Table 4.3 – Composite Rail Product Recipe .................... 14

Table 4.4 – Manufacturing Process Materials and Fuels Inventory (per lb product) ............................... 15

Table 4.5 – Packaging Inventory (per lb product) ........... 15

Table 4.6 – Installation Materials Required for 8ft Section ................................................. 16

Table 6.1 – Energy Use and Global Warming Potential During the Manufacturing of Rail and Fence Products .... 21

Table 6.2 – Environmental Impacts (BEES Methodology) of Buffalo Production Operations (per lb Produced) ....... 23

Table 6.3 – Environmental Impacts of One lb Each of Raw Materials ......................................... 24

Table 6.4 – Environmental Impact (BEES Methodology) Distribution of Vinyl Rail/Fence Formulation ................... 25

Table 6.5 – Environmental Impact (BEES Methodology) Distribution of Kingston Vinyl Rail Formulation (per lb) .. 28

Table 6.6 – Environmental Impact (BEES Methodology) Distribution of Panorama Rail Formulation (per lb) ........ 30

Table 6.7 – Bufftech Chesterfield Installation Materials (per 8ft section) ............................ 31

Table 6.8 – Bufftech New Lexington Installation Materials (per 8ft section) ............................ 32

Table 6.9 – Kingston Installation Materials (per 8ft section) .............................................................. 33

Table 6.10 – Panorama Rail Installation Materials (per 8ft section) ............................ 34

Table 6.11 – Cumulative Energy Demand (CED) for Vinyl Fence, Vinyl Rail and Composite Rail (MJ/8ft) ................ 35

Table 6.12 – Global Warming Potential (GWP) Values for Vinyl Fence, Vinyl Rail and Composite Rail (g CO2 eq/8ft) ........................................ 37

Table 6.13 – Bufftech Chesterfield Vinyl Fence Environmental Impacts per 8ft ........................................ 39

Table 6.14 – Bufftech New Lexington Vinyl Fence Environmental Impacts per 8ft ........................................ 41

Table 6.15 – Environmental Impacts of Kingston Vinyl Railing System (per 8ft) ...................... 44

Table 6.16 – Environmental Impacts of Panorama Composite Railing System (per 8ft) ........... 46

Table 7.1 – Sensitivity Analysis on the Electricity Generation Source for the FRD Manufacturing Process (per lb of Product) ..................... 48

Table 7.2 – Sensitivity Analysis on the Electricity Generation Source for the Life Cycle of CertainTeed Railing Systems ...................... 49

Table 7.3 – Overall Life Cycle Environmental Impacts of Bufftech Chesterfield Fence with and without Recycled Content ................................. 52

List of Tables


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Life cycle assessment (LCA) is a powerful tool used to quantify the environmental impacts associated with the various stages of a product’s life. Section 1 provides a background and overview of LCA methodology and benefits.

1.1 BackgroundThe use of LCA is growing rapidly in the building products market. CertainTeed and its parent company, Saint-Gobain, has been a leader in developing sustainable and innovative products. The company is developing its product stewardship program to evaluate and reduce the impacts of products and processes throughout the corporation and business groups. This report will baseline and benchmark the Bufftech, Kingston and Panorama products to assist with measuring and understanding the environmental

impacts of vinyl fence, vinyl rail and composite rail across the life cycle. The models and data developed by conducting this LCA will assist the CertainTeed Fence, Rail and Deck (FRD) group with integrating sustainable product design processes including manufacturing improvements, alternate raw materials and raw material

source locations, and other aspects to reduce environmental impacts across the life cycle for this product. This LCA is also

very valuable to CertainTeed as a tool for competitive positioning, and will provide the details to CertainTeed to take a leadership role in the field of product stewardship. It can help CertainTeed lead the possible future development of an industry product category rule (PCR).

The LCA allows CertainTeed to understand and evaluate any future data or LCA published by competitors. The LCA will also prepare CertainTeed for sustainable supply chain requirements and other policy innovations. CertainTeed has submitted this inventory data to the National Institute of Standards and Technology (NIST) to be uploaded in the life cycle database, BEES (Building for Environmental and Economic Sustainability) product LCA database.

1.0 Introduction


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Life Cycle Assessment (LCA)* is an analytical tool used to comprehensively quantify and interpret the environmental flows to and from the environment (including emissions to air, water and land, as well as the consumption of energy and other material resources) over the entire life cycle of a product (or process or service). By including the impacts throughout the product life cycle, LCA provides a comprehensive view of the environmental aspects of the product and an accurate picture of the true environmental tradeoffs in product selection.

The standards in the ISO 14040-series set out a four-phase methodology framework for completing an LCA, as shown in Figure 1: (1) goal and scope definition, (2) life cycle inventory (LCI), (3) life cycle impact assessment, and (4) interpretation. An LCA starts with an explicit statement of the goal and scope of the study; the functional unit; the system boundaries; the assumptions, limitations and allocation methods used; and the impact categories chosen. In the inventory analysis, a flow model of the technical system is constructed using data on inputs and outputs. The input and output data needed for the construction of the model are collected (including resources, energy requirements, emissions to air and water, and waste generation for all activities within the system boundaries). Then, the environmental loads of the system are calculated and related to the functional unit, to finalize the flow model. Inventory analysis is followed by impact assessment, where the LCI data are characterized in terms of their potential environmental impact (e.g., acidification, eutrophication and

global warming potential effects). The impact assessment phase of LCA is used to evaluate the significance of potential environmental impacts based on the LCI results. The impact assessment data is interpreted and validated by sensitivity analysis by the LCA practitioner to provide useful data to the company that commissioned the LCA.

The working procedure of LCA is iterative, as illustrated with the back-and-forth arrows in Figure 1.1. The iteration means that information gathered in a later stage can cause effects in a former stage. When this occurs, the former stage and the following stages have to be reworked, taking into account the new information. Therefore, it is common for an LCA practitioner to work at several stages at the same time.

1.2 Life Cycle Assessment

* This introduction is based on international standards in the ISO-14040 series, Environmental Management – Life Cycle Assessment.

Figure 1.1 The Four Stages of Life Cycle Assessment


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This LCA study is characterized as a “cradle-to-grave” study, examining vinyl fence, vinyl rail and composite rail systems from raw material extraction through final disposal. For this life cycle assessment, Sustainable Solutions Corporation (SSC) collected specific data on energy and material inputs, wastes, water use, emissions, and transportation impacts for the specified products based on production in Buffalo, NY for the calendar year 2013. This LCA was conducted using SimaPro software with the National Renewable Energy Lab (NREL) US LCI database serving as the primary source of life cycle inventory data for raw materials and processes not directly collected from Buffalo, NY. Where data was not available in the US LCI database, data from the ecoinvent LCI database, private SSC LCI databases, and published reports were used. Data from European databases was adapted using US electricity impacts. The BEES+ 4.04 impact assessment methodology was used to calculate the environmental impacts in this LCA. BEES was developed

by the National Institute of Standards and Technology (NIST) as a tool to assist in impact analysis in Life Cycle Assessments, process design, and pollution prevention. Impact categories include:

1. Global Warming Potential

2. Acidification

3. Human Health

4. Criteria Air Pollutants

5. Eutrophication

6. Smog

7. Fossil Fuel Depletion

8. Indoor Air Quality

9. Habitat Alteration

10. Ozone Depletion

Potential benefits of a life cycle assessment include: better materials sourcing, manufacturing process environmental impact reduction, education, evaluation of raw materials, impacts to product standards, decreased air emissions, waste reduction, increased recycling, reduced water use, and cost savings, among many others.

1.2 Life Cycle Assessment (continued)


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The nature of life cycle assessment is to include a wide range of inputs associated with the product being analyzed. Constraining the LCA scope is an essential part of the study. The following section defines the goal, scope, and boundaries of this LCA study.

2.1 Goal of the StudyThe goal of this analysis is to identify and quantify the environmental impacts associated with each stage in the life cycle of the vinyl fence, vinyl rail and composite rail products, including raw material extraction, processing, and shipping; manufacturing; final product shipping; product use; and end-of-life disposition.

Intended Uses

LCA is a tool that can effectively be applied for manufacturing process improvements, education and market support, environmental management, and sustainable reporting. CertainTeed, who is the primary audience of the study, intends to use the study results mainly for the following purposes:

• Provide a baseline LCA in order to understand and evaluate the impacts of the Vinyl Fence, Vinyl Rail and Composite Rail across the product life cycle.

• Product Stewardship – LCA is a tool in the CertainTeed Fence, Rail and Deck product stewardship program. This LCA will be used by the CertainTeed Fence, Rail and Deck new product development team members to quantify and understand the impacts of the products and processes throughout the life cycle in order to integrate sustainable product design techniques to reduce the impacts, to the extent possible.

• Process Improvements and New Technology Evaluation

– CertainTeed FRD can use the completed LCA to evaluate possible process improvements in the manufacture of fence and railing products produced at CertainTeed facilities. Based on the results, they can evaluate alternate ingredients or raw materials, opportunities for integration of recycled content or bio based materials, and opportunities for designing a closed loop product in the future.

• Position CertainTeed Fence, Rail and Deck as an industry leader in product stewardship.

• Prepare CertainTeed for sustainable supply chain requirements, carbon taxes, and other potential policy requirements.

• Provide competitive analysis and positioning in order to analyze and evaluate claims or LCA / EPD information published in the future by competitors.

• As a basis for publication in the BEES product database.

• As a tool to illustrate the reduced environmental impacts to regulatory agencies such as the U.S. EPA of process, facility or raw material improvements.

• To meet future requirements for green purchasing programs for the United States Government, corporations, or other businesses.

2.0 Goal and Scope Definition


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All flows to and from the environment within the system boundary (see Section 2.3) are normalized to a unit summarizing the function of the system. The function of fence is to provide privacy and security along property perimeters. Railings provide safety and aesthetics along the edge of decks, porches, stairs and other areas.

Once the primary functions of the systems are defined, a functional unit is selected in order to provide a similar basis, consistent with the above mentioned goals, for summarizing the LCA. The functional unit utilized for this study is an eight feet (8ft.) section of fence or railing with a service life of 25 years for railing systems and 50 years for fencing systems, including end-of-life disposition. This functional unit is consistent with the goal and scope of the study. Tables 2.1-2.2 list specific details of the Bufftech®, Kingston, and Panorama® products which are representative products of the product lines produced in Buffalo for vinyl fence, vinyl rail and composite rail, respectively.

The functional unit determines the environmental impacts and is the basis for comparison in an LCA. It provides a unit of analysis and comparison for all environmental impacts.

2.2 Functional Unit

Bufftech® Vinyl Fence

Chesterfield New Lexington

Manufacturing Location Buffalo, NY Buffalo, NY

Functional Unit 8ft 8ft

Weight 70.48 lb 52.82 lb

Lifetime 50 years 50 years

Product Function Privacy and Aesthetics

Privacy and Aesthetics

Table 2.1 Bufftech ® Vinyl Fence Product Details

Kingston Vinyl Railing

System

Panorama Composite Railing

System

Manufacturing Location Buffalo, NY Buffalo, NY

Functional Unit 8ft 8ft

Weight 28.69 lb 44.01 lb

Lifetime 25 years 25 years

Product Function Aesthetics and Safety

Aesthetics and Safety

Table 2.2 Kingston Vinyl Rail Product Details


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This project considers the life cycle activities from resource extraction through product use for a 25 year life cycle inclusive of maintenance and end-of-life effects. Maintenance during the product’s use phase includes occasional cleaning with soapy water; as the cleaning frequency is variable and often not executed in real world practice, this was excluded from the scope of this study. Figure 2.1 defines the system boundary for this study. The study system boundary includes the transportation of major inputs to (and within) each activity stage including the shipment of final products to the use site, based on logistics data provided by CertainTeed by common modes, as well as transportation to a landfill at the end of the service life. Any site-generated energy and purchased electricity is included in the system boundary. The extraction, processing and delivery of purchased primary fuels, e.g., propane and primary fuels used to generate purchased electricity, are also included within the boundaries of the system. Purchased electricity consumed at the Buffalo site location is modeled using hydropower generation, based on the power purchase agreement between the electricity provider and CertainTeed.

Both human activity and capital equipment were excluded from the system boundary. The environmental effects of manufacturing and installing capital equipment and buildings have generally been shown to be minor relative to the throughput of materials and components over the useful lives of the buildings and equipment. Human activity involved in the manufacture of fencing and rail products and their component materials no doubt has a burden on the environment; however, the data collection required to properly quantify human involvement is

particularly complicated, and allocating such flows to the production of these products, as opposed to other societal activities, was not feasible for a study of this nature. Typically, human activity is only considered within the system boundary when value-added judgments or substituting capital for labor decisions are considered to be within the scope of the study; however, these types of decisions are outside this study’s goal and scope. The details of the data excluded from the system boundary can be found in the subsequent inventory sections.

2.3 System Boundary

Figure 2.1 System Boundary for Vinyl Fence, Vinyl Rail and Composite Rail


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2.3.1 Cut-off Criteria

Processes whose total contribution to the final result, with respect to their mass and in relation to all considered impact categories, is less than 1% can be neglected. The sum of the neglected processes may not exceed 5% by mass and by 5% of the considered impact categories. For that a documented assumption is admissible.

For Hazardous Substances, as defined by the U.S. Occupational Health and Safety Act, the following requirements apply:

• The Life Cycle Inventory (LCI) of hazardous substances will be included, if the inventory is available.

• If the LCI for a hazardous substance is not available, the substance will appear as an input in the LCI of the product, if its mass represents more than 0.1% of the product composition.

• If the LCI of a hazardous substance is approximated by modeling another substance, documentation will be provided.

This LCA is in compliance with the cut-off criteria since only potential installation energy was neglected or excluded from this analysis outside of the specific items listed under “Excluded” in Table 2.3.

For the disposal phase, the product was modeled as materials sent to landfill, as this is the most common way of dealing with these products at the end-of-life.

2.3 System Boundary (continued)

Included Excluded

Raw material acquisition and processing Construction of capital equipment

Maintenance of operation and support equipment

Human labor and employee commute

Occasional cleaning during use

Energy required for installation

Accessory materials such as gates and post lights

Processing of materials

Transport of raw materials

Energy used in production (lighting, heating, cooling, etc.) at manufacturing facilities

Interplant and final product shipping

Packaging

Manufacturing waste and emissions

Installation materials

Product disposal

Table 2.3 System Boundary Description


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The quality results of an LCA study are directly dependent on the quality of input data used in the model. This section describes the data quality guidelines used in this study, the sources from which the data was selected, the software used to model the environmental impacts, and any data excluded from the scope of the study.

3.1 Data QualityWherever secondary data is used, the study adopts critically reviewed data for consistency, precision, and reproducibility to limit uncertainty. The data sources used are complete and representative of North America in terms of the geographic and technological coverage and are a recent vintage (i.e. less than ten years old). Any deviations from these initial data quality requirements for secondary data are documented in the report.

The results of an LCA are only as good as the quality of input data used. Important data quality factors include precision (measured, calculated or estimated), completeness (e.g., unreported emissions or excluded flows), consistency (uniformity of the applied methodology throughout the study), and reproducibility (ability for another researcher reproduce the results based on the methodological information provided). The primary data from the manufacturer was from the latest data available. Each dataset used was taken from SimaPro databases, either US LCI or ecoinvent. These databases are widely distributed and referenced within the LCA community and are either partially or fully critically reviewed.

Precision

The data used for primary data are based on direct information sources of the manufacturer. The energy and water usage data was collected directly from the utility meters, and the allocation was based on production at the plant. Therefore the precision for primary data is considered high; however, the uncertainty of the primary data has not been quantified.

Secondary data sets were used for raw materials extraction and processing, end of life, transportation, and energy production flows. The US ecoinvent database was used for most of the raw material data sets. Since the inventory flows for ecoinvent processes are very often accompanied by a series of data quality ratings, a general indication of precision can be inferred. Using these ratings, the data sets used generally have medium-to-high precision. Precision for the datasets used from the US LCI database was not formally quantified. However, many data sets from the US LCI were developed based on well-documented industry averages with data quality indicators provided for each flow.

Completeness

The processes modeled represent the specific situations in vinyl fence, vinyl rail and composite rail life cycles. System boundaries and exclusions are clearly defined in the sections above, and no other data gaps were identified.

3.0 Data Sources and Modeling Software


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Consistency

Primary data was collected from the CertainTeed FRD experts as tracked by World Class Manufacturing automated systems and records. Since most of the data is annually reported, the consistency is considered high. Secondary data was consistently modeled using either US LCI or ecoinvent databases as available. Proxies were only identified and used if secondary data was not available in these or other databases. This methodology provides consistency throughout the model.

Reproducibility

Most datasets are from nationally accepted and publicly available databases, ensuring reproducibility by an average practitioner. Confidential data from the plant would inhibit reproducing these results without access to the data.

Representativeness

The representativeness of the datasets is chosen to be representative of North America, average technologies of the major producers and distributors and of recent and modern vintage.

Uncertainty

Most of the secondary data sets in US LCI and ecoinvent databases have some uncertainty information documented and varies per model. Uncertainty for primary data was not quantified. However, the collected data and allocation methodologies were judged by the operations personnel to be accurate, so the uncertainty is considered low.

The primary data from the manufacturer was from the latest data available, incorporating the most recent updates to the process into the model. Each dataset used was taken from SimaPro databases, either US LCI or ecoinvent. These databases are widely distributed and referenced within the LCA community. The datasets use relevant yearly averages of primary industry data or primary information sources of the manufacturer and technologies. The uncertainty of each dataset is not formally quantitatively known. Each dataset is from publicly available databases, ensuring reproducibility. The representativeness of the datasets is chosen to be representative of North America, average technologies of the major producers and distributors and of recent and modern vintage. Below is a more detailed description of the datasets used in the model of raw materials extraction and processing for the major components of vinyl fence, vinyl rail and composite rail.

3.2 Data SourcesNorth America is considered as the geographic boundary of this study. The reference year is 2013 since the primary CertainTeed Vinyl Fence, Vinyl Rail and Composite Rail manufacturing data were gathered for that calendar year. Both primary and secondary LCI and metadata are used throughout the study. All secondary data is taken from literature, previous LCI studies, and life cycle databases. The US LCI database (www.nrel.gov/lci) is frequently used in this analysis. Much of the LCI data residing in the US LCI database pertain to common fuels – their combustion

in utility, stationary and mobile equipment inclusive of upstream or pre-combustion effects (i.e. back to earth). Generally, these modular data are of a recent vintage (less than ten years old). This study draws on these data for combustion processes, electricity generation, and transportation on a regional North American basis. These data are free and publicly available, and thus, offer both a high degree of transparency and an ability to replicate the results of the study; however, there are limitations, as some processes are missing for some of the products available in this LCI database, creating an issue with respect to completeness.

When North American data was not available for a product or process, the European ecoinvent LCI database was utilized. This database contains over 3,500 LCI modules for processes and products, all of which have undergone peer review. The basic assumption when using these data is that North American and European production processes are generally similar, but that these data need to be adapted for North American circumstances (e.g., electricity grids, fuels and transportation modes and distances need to be modified to better reflect the North American operations). Such adaptation was conducted whenever necessary.

3.1 Data Quality (continued)


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3.2 Data Sources (continued)Table 3.1 Data Sources for Vinyl Fence, Vinyl Rail and Composite Rail

(continued next page)

Material Input Database(s) and Source Temporal Information Regional Coverage Technology Coverage Data Type

Wood/PVC Regrind Composite (Panorama only)

Proxy – Assumed cut-off methodology for recycled material; processing energy based on specific data from Return Polymers

2011 North America Supplier specific Primary

Calcium Carbonate US LCI – as Limestone 2008 United States Quarried from open pits by blasting, followed by mechanical crushing and

screening

Secondary

External PVC Regrind Proxy – Assumed cut-off methodology for recycled material; processing energy based on specific data from Return Polymers

2011 North America Supplier specific Primary

Calcium Stearate Quicklime – US LCI, Fatty acids, ecoinvent 2000s Data

North America and Europe, adapted to US

Conditions via EarthShift

Most recent technology Secondary

Impact Modifier – Arkema 91% polymethyl methacrylate (proxy for “proprietary acrylate polymer”), 5% Calcium carbonate, 5% ethoxylated alcohol (proxy for surfactact)

2008 North America and Europe, adapted to US


Mix of technologies for proxy

Proxy

Impact Modifier Acrylic filler, ecoinvent; Methyl methacrylate, ecoinvent 2000s Data

Europe, adapted to North American

conditions via EarthShift

50% Acrylic filler, 50% MMA

Secondary

Oxidized Polyethylene Paraffins, ecoinvent and Polyethylene, US LCI 2000s Data



Supplier Specific Secondary

Paraffin Paraffins, ecoinvent 2000s Data



Average technologies Secondary

Polyethylene Wax Paraffins, ecoinvent and Polyethylene, US LCI 2000s Data



Supplier specific Secondary

PVC Resin Previous LCA Study from Lake Charles Facility 2012 Facility specific Facility specific Primary


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3.2 Data Sources (continued)Table 3.1 Data Sources for Vinyl Fence, Vinyl Rail and Composite Rail (continued)

Material Input Database(s) and Source Temporal Information Regional Coverage Technology Coverage Data Type

Tin Heat Stabilizer Proxy developed from processes in ecoinvent – see Section 3.2.2 2000s Data



see Section 3.2.2 Secondary

Titanium Dioxide Titanium dioxide, ecoinvent 2000s Data



50% sulfate process and 50% chloride process

Secondary

Process Input Database(s) and Source Temporal Information Regional Coverage Technology Coverage Data Type

Electricity, hydropower, at plant

ecoinvent v2.2 2007 Europe, adapted to North American


Mix of multiple hydropower generation

technologies

Secondary

Propane US LCI 2008 US average Combustion of liquefied petroleum gas and average emissions

Secondary

Water Tap water, ecoinvent v3 2007 Europe, adapted to rest of the World conditions

Water treatment and transportation to end user

Secondary

STABROM 909 Proxy – biocide, ecoinvent v2.2 2013 Europe, adapted to North American


Average of multiple biocides

Proxy

Stabrex ST70 Proxy – biocide, ecoinvent v2.2 2013 Europe, adapted to North American


Average of multiple biocides

Proxy

Corrosion Inhibitor Proxy – Solution corrosion inhibitor ecoinvent v2.2 2013 Europe, adapted to North American


Average of multiple solution corrosion inhibitors

Proxy

Trasar Trac101 30% sodium nitrate, 50% molybdenite, 20% water, ecoinvent v3 2013 European, adapted for Rest of World conditions


Proxy

CL7200 Proxy – Trasar Trac101 2013 European, adapted for Rest of World conditions


Proxy



12

3.2 Data Sources (continued)Table 3.1 Data Sources for Vinyl Fence, Vinyl Rail and Composite Rail (continued)

Installation Materials Database(s) and Source Temporal Information Regional Coverage Technology Coverage Data Type

Aluminum Inserts Aluminum, secondary – US LCI 2008 US average National average Secondary

Concrete Footing Proxy – Concrete Block, ecoinvent v3 2013 Europe, adapted to Global conditions via

EarthShift

Normal concrete poured into a mold and air-dried

Secondary

Post Caps PVC Product Formulation 2013 Facility specific Extrusion Secondary

Hardware Stainless steel, ecoinvent v2.2 2007 Europe, adapted to North American


European technology mix

Secondary

Kits PVC Product Formulation 2013 Facility specific Extrusion Secondary

Steel Inserts Stainless steel, ecoinvent v2.2 2007 Europe, adapted to North American


European technology mix

Secondary

End of Life Database(s) and Source Temporal Information Regional Coverage Technology Coverage Data Type

Waste treatment to sanitary landfill

US – ecoinvent v3 2000 European – adapted to US Conditions

Waste-specific short-term emissions to air via landfill gas incineration and landfill leachate. Burdens from treatment of short-

term leachate (0-100a) in wastewater treatment plant (including WWTP sludge disposal in municipal incinerator). Long-term

emissions from landfill to groundwater (after base lining failure).

Secondary

Transportation Database(s) and Source Temporal Information Regional Coverage Technology Coverage Data Type

Truck Freight US LCI 2000s Data North America Average Technologies Primary

Rail Freight US LCI 2000s Data North America Average Technologies Primary

Ocean Freighter US LCI 2000s Data North America Average Technologies Primary



13

3.2.1 Heat Stabilizer

An expert in PVC heat stabilizers, Rob Martin, was contacted from Dow Chemical to discuss a valid proxy to model this component. Based on his comments, the heat stabilizer model uses 9.5% tin for methyltin mercaptoester sulfides which constitute around 60% of the heat stabilizer. Additionally, between 1% and 5% mercaptoester are used in the heat stabilizer and around 25% of mercaptoethyltallate or mercaptoethanol are varied according to market price.

As proxies for the mercaptan materials, materials used in the model include 11.3% chlorine (estimate based on production process of akyltin mercaptoester sulfide), 7.7% magnesium (estimate based on production process of akyltin mercaptoester sulfide, 33.5% fatty acids (estimate based on production process of akyltin mercaptoester sulfide), 1.3% hydrogen sulfide (1:1 molar ratio with ethylene oxide for proxy of mercaptoethanol), 1.7% ethylene oxide (1:1 molar ratio with hydrogen sulfide for proxy of mercaptoethanol) †, 17.5% fatty acids (proxy for mercaptoethyltallate), 17.5% fatty acids (proxy for mercaptoethyloleate).

3.3 Modeling SoftwareSimaPro v8.0 software was utilized for modeling the complete cradle-to-grave LCI for vinyl fence, vinyl rail and composite rail. All process data including inputs (raw materials, energy and water) and outputs (emissions, waste water, solid waste, and final products) are evaluated and modeled to represent each process that contributes to the life cycle of the vinyl fence, vinyl rail and composite rail products. The study’s geographical and technological coverage has been limited to North America, focusing on the region around Buffalo, NY where applicable. SimaPro was used to generate life cycle impact assessment (LCIA) results utilizing the BEES impact assessment methodology as well as single flow environmental scores (Global Warming Potential and Cumulative Energy Demand). See Section 5.2 for a description of the selected LCIA categories and characterization measures used in this study.

3.2 Data Sources (continued)

† Knight, J.J.“2-Mercaptoethanol in Encyclopedia of Reagents for Organic Synthesis (Ed: L. Paquette) 2004.


14

This section describes the cradle-to-grave life cycle inventory of vinyl fence, vinyl rail and composite rail. Primary manufacturing data was collected from surveys completed by personnel from the manufacturing plant located in Buffalo, NY for the 2013 calendar production year. The participating manufacturing plant provided resource transportation mode and distance data to support the calculation of raw material transportation flows. The transportation LCI data from the US LCI database (kg-km basis) were used to develop the resource transportation LCI profile.

4.1 Raw Materials and Product Recipe OverviewA thorough analysis of the material inputs and the product recipe was completed for the inventory of this study. The vinyl fence, vinyl rail and composite rail product recipes are listed in Table 4.1 through Table 4.3.

4.0 Life Cycle Inventory AnalysisTable 4.1 Vinyl Fence (Bufftech®) Product Recipe

Bufftech® Recipe Chesterfieldlbs / 8ft

New Lexingtonlbs / 8ft

PVC resin 38.41 28.79

Titanium dioxide 1.13 0.85

Polyethylene wax 0.14 0.11

Calcium stearate 0.56 0.42

Paraffin 0.78 0.58

Stabilizer 0.49 0.37

Impact modifier (Elkem) 0.39 0.30

Impact modifier (Arkema) 0.85 0.63

Calcium carbonate 5.22 3.91

External regrind 22.55 16.90

Table 4.2 Vinyl Rail Product Recipe Table 4.3 Composite Rail Product Recipe

Kingston Recipe Kingstonlbs / 8ft

PVC resin 15.63

Titanium dioxide 0.46

Polyethylene wax 0.05

Calcium stearate 0.23

Paraffin 0.32

Stabilizer 0.20

Impact modifier (Elkem) 0.34

Impact modifier (Arkema) 0.16

Calcium carbonate 2.12

External regrind 9.18

Panorama® Recipe Panorama®

lbs / 8ft

Wood/Plastic Composite Regrind 39.61

PVC 3.61

Titanium dioxide 0.35

Polyethylene wax 0.01

Calcium stearate 0.04

Paraffin 0.05

Stabilizer 0.04

Impact modifier (Arkema) 0.11

Calcium carbonate 0.19


15

4.2 Manufacturing Process OverviewA detailed analysis of the manufacturing process was completed by Sustainable Solutions Corporation, including a site visit on June 3, 2014 to Buffalo, NY to observe and understand the manufacturing process.

The Buffalo plant is the only CertainTeed location that produces vinyl fence, vinyl rail and composite rail for CertainTeed. The Buffalo plant produces a variety of FRD products with differing impacts, so allocation was conducted based on run hours and production per hour. Overhead energy and water consumption was included in the allocation.

To produce fencing and railing systems, energy, water and materials go into the process and waste and emissions are outputs from the manufacturing process. An inventory was conducted and, based on the allocation described above, Table 4.4 details the process inputs and outputs and Table 4.5 details how the products are packaged.

Energy Inputs Quantity Unit

Electricity 4.55E-01 kWh

Propane 1.31E-02 kWh

Table 4.4 Manufacturing Process Materials and Fuels Inventory (per lb product)

Packaging Panorama® Kingston Bufftech® Unit

Pallets 5.53E-02 5.53E-02 5.53E-02 lb packaging / lb produced

Cut to size lumber 2.31E-01 2.31E-01 – lb packaging / lb produced

8ft lumber 7.24E-02 7.24E-02 – lb packaging / lb produced

Cardboard slip sheet 4.18E-03 4.18E-03 4.18E-03 lb packaging / lb produced

White film 1.83E-02 1.83E-02 – lb packaging / lb produced

Clear film 1.60E-02 1.60E-02 9.85E-03 lb packaging / lb produced

Green strapping 1.48E-03 1.48E-03 1.48E-03 lb packaging / lb produced

Boxes 3.83E-03 7.16E-03 – lb packaging / lb produced

Table 4.5 Packaging Inventory (per lb product)

Water Quantity Unit

Water inflow 1.68E-01 gal

Water outflow 6.82E-02 gal

Waste Quantity Unit

Pulverized ASA/ AES (recycled)

5.86E-02 lbs

Waste to energy 1.36E-02 lbs

Hazardous waste 8.65E-05 lbs


16

Final products were modeled as being shipped 717 miles by truck for distribution.

4.4 Installation The installation of fence and railing systems require additional materials per section of fence/rail. As any energy required from power tools to install the products are significantly smaller than energy required to manufacture the products and meets the cut-off criteria, this energy was excluded. The required installation materials are detailed in Table 4.6.

During the use phase, the products may be cleaned with soapy water; however, this was excluded from the scope.

4.5 End of LifeAn average of 25 years is suggested as the likely life of most vinyl Rail and composite rail products. Lifetime warranties are provided by CertainTeed for fence products, so a lifetime of 50 years can be assumed for vinyl fence. The products’ end-of-life assumed to be inert in a landfill. This gate-to-grave flow data were combined with resource extraction and processing data.

4.3 Distribution

Installation MaterialBufftech®

Chesterfield Fence

Bufftech® New Lexington

Fence

Kingston Railing System

Panorama®

Railing System Unit

CertainTeed section 70.48 52.82 28.69 44.01 lbs

Posts and post caps (including 2 posts) 17.57 14.52 9.53 11.01 lbs

Hardware 3.92 3.92 – 3.76 lbs

Steel insert 5.94 6.42 – – lbs

Aluminum insert (90% recycled content) – – 6.8 – lbs

Bracket kit – – 0.97 – lbs

Concrete footing 100 100 – – lbs

Miscellaneous – – – 2.09 lbs

Table 4.6 Installation Materials Required for 8ft Section


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5.0 Life Cycle Impact Assessment (LCIA)The environmental impacts of a product can be categorized and presented in many ways. This section briefly describes the methodology used to develop the impact assessment and defines the selected impact categories used to present the results. This section also lists assumptions of the study and describes the inherent limitations and uncertainty of the LCA results.

5.1 Impact Categories / Impact AssessmentAs defined in ISO 14040:2006, “the impact assessment phase of an LCA is aimed at evaluating the significance of potential impacts using the results of the LCI analysis”. In the LCIA phase, SSC modeled a set of selected environmental issues referred to as impact categories and used category indicators to aggregate similar resource usage and emissions to explain and summarize LCI results data. These category indicators are intended to “characterize” the relevant environmental flows for each environmental issue category to represent the potential or possible environmental impacts of a product system.

ISO 14044 does not specify any specific methodology or support the underlying value choices used to group the impact categories. The value-choices and judgments within the grouping procedures are the sole responsibilities of the commissioner of the study.

The framework surrounding LCIA includes three steps that convert LCI results to category indicator results. These include the following:

1. Selection of impact categories, category indicators and models.

2. Assignment of the LCI results to the impact categories (classification) – the identification of individual inventory flow results contributing to each selected impact indictor.

3. Calculation of category indicator results (characterization) – the actual calculation of the potential or possible impact of a set of inventory flows identified in the previous classification step.

To maximize the reliability and flexibility of the results, SSC used an established impact methodology for assigning and calculating impacts. The Building for Environmental and Economic Sustainability (BEES) methodology was used for all calculations of environmental impact. BEES was developed by the National Institute of Standards and Technology (NIST) to assist in impact analysis in Life Cycle Assessments, process design, and pollution prevention.


18

While LCI practice holds to a consistent methodology, the LCIA phase is an evolving science and there is no overall generally accepted methodology for calculating all of the impact categories that might be included in an LCIA. Typically, the LCIA is completed in isolation of the LCI. The LCI involves the collection of a complete mass and energy balance for each unit process under consideration. Once completed, the LCI flows are sifted through various possible LCIA indicator methods and categories to determine possible impacts. Due to the North American focus of this LCA study, the BEES+ 4.04 LCIA methodology was used to characterize the study’s LCI flows. Impact categories include:

1. Global Warming Potential (g CO2 eq) – Carbon dioxide and other greenhouse gasses are emitted whenever fossil fuels are burned and from a number of other human activities. These gasses can trap heat close to the Earth, contributing to global warming. A general increase in temperature can alter atmospheric and oceanic temperatures, which can potentially lead to alteration of ocean currents and weather patterns, as well as rising sea levels. The global warming potential of an activity emission is calculated on the basis of the grams of carbon dioxide equivalents.

2. Acidification (H+ moles eq) – Acidification is a more regional, rather than global impact, affecting fresh water and forests as well as human health when high concentrations of sulfur and nitrogen compounds are attained. Acidification can kill trees and make water and soil less able to support plant and animal life. The acidification potential of an air emission is calculated on the basis of the number of H+ ions that can be produced and, therefore, is expressed as potential H+ equivalents on a mass basis.

3. Human Health: Cancer & Non-cancer (g C6H6 eq + g C7H7 eq) – This impact assesses the potential health impacts of more than 200 chemicals. These health impacts are general, based on emissions from the various life cycle stages, and do not take into account increased exposure that may take place in manufacturing facilities. In measuring the potential contribution to cancer, the Toxic Equivalency Potential for each chemical is determined and is displayed in terms of benzene equivalents. In measuring contribution to health impacts other than cancer, the Toxic Equivalency Potential for each chemical is determined and is displayed in terms of toluene equivalents.

4. Criteria Air Pollutants (microDALYS) – These are commonly found air pollutants. They include particle pollution (often referred to as particulate matter), ground-level ozone, carbon monoxide, sulfur oxides, nitrogen oxides, and lead. These pollutants can cause harm to human health and the environment. This impact measures the amounts of the criteria air pollutants: nitrogen oxides, sulfur oxides, and particulate matter. Lead, ground level ozone, and carbon monoxide are captured in other impacts.

5. Eutrophication (g N eq) – Eutrophication is the fertilization of surface waters by nutrients that were previously scarce. When a previously scarce or limiting nutrient is added to a water body, it leads to the proliferation of aquatic photosynthetic plant life. This may lead to the water body becoming hypoxic, eventually causing the death of fish and other aquatic life. This impact is expressed on an equivalent mass of nitrogen (N) basis.

6. Ecotoxicity (g 2,4-D eq) – The ecological toxicity impact measures the potential of a chemical released into the environment to harm terrestrial and aquatic ecosystems. This potential is measured in terms of 2,4-dichlorophenoxy-acetic acid (2,4-D) equivalents.

7. Smog (g NOx eq) – Under certain climatic conditions, air emissions from industry and transportation can be trapped at ground level where, in the presence of sunlight, they produce photochemical smog, a symptom of photochemical ozone creation potential (POCP). While ozone is not emitted directly, it is a product of interactions of volatile organic compounds (VOCs) and nitrogen oxides (NOx). The Smog indicator is expressed as a mass of equivalent NOx.

8. Natural Resource Depletion (MJ surplus) – This impact measures the use of extracted fossil fuels (petroleum, coal, and natural gas).

9. Indoor Air Quality (kg TVOC eq) – It measures the effects of products on the air quality inside buildings, primarily through the measurement of volatile organic compound (VOC) emissions. As no indoor air emissions are tracked through CertainTeed or their suppliers, this impact category was removed from the analysis.

10. Habitat Alteration (T&E Count) – This impact measures the potential for land use by humans to lead to damage of Threatened and Endangered Species. In BEES, habitat alteration is assessed based on the amount of waste sent to landfill through the life of the product and at the point of final disposal.

5.2 Selected Impact Categories


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11. Ozone Depletion (g CFC-11 eq) – Certain chemicals, when released into the atmosphere, can cause depletion of the ozone layer, which protects the Earth and its inhabitants from certain types of harmful radiation. This impact measures the releases of those chemicals in terms of CFC-11 equivalents.

Primary energy use on a cumulative energy demand basis is tabulated and summarized as an impact category directly from the LCI flow results. Energy use is a key impact indicator over which manufacturers are likely to assert a considerable level of control and, therefore, is a good internal target for resource conservation. Cumulative energy demand is the sum of all energy sources drawn directly from the earth, such as natural gas, oil, coal, biomass, or hydropower energy. The total primary energy contains further categories, namely non-renewable and renewable energy, and feedstock energy.

5.3 Manufacturing Process Allocation and AssumptionsLife cycle analysis requires that assumptions are made to constrain the project boundary or model processes when little to no data is available. In this study of fencing and railing products, the following assumptions were made:

• Solid waste is sent for waste-to-energy.

• When a material is not available in the available LCI databases, another chemical which has similar manufacturing and environmental impacts may be used as a proxy, representing the actual chemical. The Proxy Chemical List used in this analysis includes:

– Composite decking:

• The wood/plastic composite regrind decking material was assumed the raw material extraction is burden-free due to the cut-off methodology

• Regrind energy submitted from Return Polymers was assumed to be equivalent for processing of this material.

– Heat Stabilizer: 9.5% tin, 11.3% chlorine, 7.7% magnesium, 33.5% fatty acids, 1.3% hydrogen sulfide, 1.7% ethylene oxide, 35% fatty acids.

– Calcium Stearate: 9% Quicklime and 91% fatty acids.

– Water Treatment Chemicals: If no water treatment chemical was available to match the MSDS of the manufacturing facility, the ecoinvent biocide process was used as a proxy. See Table 3.2 for more details.

– Oxidized Polyethylene: high density polyethylene resin.

5.4 Initial Service and End-of-Life AssumptionsThe study assumes the service life is 25 years for railing systems and 50 years for fencing products; the end-of-life disposition is modeled as landfilled. The selected service life used in the project reflects the expert opinions of the product manufacturers. Disposal in a municipal landfill or in commercial incineration facilities is permissible and should be done in accordance with local, state, and federal regulations.

5.2 Selected Impact Categories (continued)


20

This section presents the results of the LCA study. It includes energy, global warming, and other quantified impacts for each of the BEES impact categories.

6.1 Manufacturing ImpactsA manufacturer chooses the raw materials and processes that will be used to produce a product, but their ability to directly influence the processing, and thus environmental impact, of raw materials is typically outside of the manufacturer’s control. Figure 6.1 – Life cycle stage control diagram below illustrates the total life cycle of a product from raw materials extraction and processing through installation, use and end-of-life. Environmental impacts that occur in raw material shipping, manufacturing, and final product shipping are directly under CertainTeed Fence, Rail and Deck’s control. This puts much of the environmental impact of the final product out of the control of CertainTeed Fence, Rail and Deck, unless material substitutions can be made.

6.0 Vinyl Fence, Vinyl Rail and Composite Rail LCA Results

Figure 6.1 Life Cycle Stage Control Diagram


21

6.1.1 Manufacturing Energy and Carbon Analysis

Energy is required to extract, process, and ship raw materials to the plant, manufacture the product and ship the final product to the customer.

Table 6.1 lists the amount of cumulative energy consumed for the manufacturing process, those processes most directly under the control of CertainTeed. All of the energy consumption was converted to megajoules (MJ) to allow for comparison of energy consumption across all uses. This energy consumption is based on the original manufacturing inventory in Section 4.2 where allocation and fuels and energy sources are discussed.

Figure 6.2 and Figure 6.3 show the same distribution in pie charts. This further illustrates the overwhelming contribution that electricity consumption contributes to energy consumed to produce fence, rail and deck products in Buffalo.

While electricity is the largest energy consumer at the facility for the process, the Buffalo facility has a power purchase agreement between the local hydropower generator. Based on this agreement, the electricity provided to the facility is 100% hydropower generated and therefore has less upstream energy consumption impacts compared to the average electricity grid. A sensitivity analysis on the electricity mix is further investigated in Section 7.

6.1 Manufacturing Impacts (continued)

Cumulative Energy Demand

MJ / lb

Global Warming Potential

gCO2 / lb

Electricity 1.7E+00 2.7E+00

Propane 2.7E-03 4.3E-02

Water 8.6E-03 6.0E-01

Waste and Scrap 1.4E-02 2.2E+0

Fuel / Ancillary Material Transport 4.9E-02 3.5E+00

Total 1.8E+00 9.9E+00

Table 6.1 Energy Use and Global Warming Potential During the Manufacturing of Rail and Fence Products

Figure 6.2 Energy Distribution of the Buffalo Manufacturing Process


22

6.1.1 Manufacturing Energy and Carbon Analysis (continued)

While electricity is the largest driver of cumulative energy demand, waste disposal is the largest driver of global warming impacts for manufacturing fence, rail and deck products. As the Buffalo facility sends solid waste to a waste-to-energy facility, the carbon emissions from the incineration of the waste drives the manufacturing carbon footprint.

6.1.2 Additional Environmental Impacts from Manufacturing

Besides energy demand and carbon emissions, manufacturing impacts other impacts as well. A BEES analysis was run for the manufacturing phase. Figure 6.2 shows the overall trends of the manufacturing phase at the Buffalo plant.

6.1 Manufacturing Impacts (continued)Figure 6.3 Global Warming Potential Distribution to Manufacture Vinyl Rail and Fence Products


23

6.1.2 Additional Environmental Impacts from Manufacturing (continued)

As shown in Figure 6.4, the manufacturing impacts are primarily driven by the electricity consumed by the Buffalo facility during the manufacturing process, water use and material transport. Electricity is the driver of the human health noncancer, human health criteria air pollutants, and ecotoxicity. Water use is the main driver of human health cancer, eutrophication, habitat alteration and water intake. The ancillary material transportation to and from the facility drives the potential impact categories: acidification, smog, natural resource depletion and ozone depletion.

6.1 Manufacturing Impacts (continued)Figure 6.4 Environmental Impacts (BEES Methodology) of Buffalo Production Operations (per lb Produced)

Table 6.2 Environmental Impacts (BEES Methodology) of Buffalo Production Operations (per lb Produced)

Impact Category Unit (per lb) Electricity Propane Water Waste and Scrap Material Transport Total

Global warming g CO2 eq 2.7E+00 4.3E-02 6.0E-01 3.1E+00 3.4E+00 9.9E+00

Acidification H+ mmole eq 5.2E-01 1.4E-02 4.8E-01 7.1E-02 7.8E-01 1.9E+00

HH cancer g C6H6 eq 1.5E-02 1.1E-04 1.9E-02 1.7E-03 2.6E-03 3.8E-02

HH noncancer g C7H7 eq 2.4E+01 1.3E-01 1.6E+01 3.0E+00 2.7E+00 4.6E+01

HH criteria air pollutants microDALYs 1.2E-03 4.4E-06 1.4E-04 3.1E-05 2.2E-04 1.6E-03

Eutrophication g N eq 4.0E-03 4.4E-05 7.6E-03 8.6E-03 2.0E-03 2.2E-02

Ecotoxicity g 2,4-D eq 3.7E-02 1.7E-04 9.8E-03 2.1E-03 4.3E-03 5.3E-02

Smog g NOX eq 9.2E-03 1.6E-04 9.6E-03 7.3E-04 2.0E-02 3.9E-02

Natural resource depletion MJ surplus 1.8E-03 3.8E-04 2.4E-03 1.3E-04 4.6E-03 9.3E-03

Habitat alteration T&E count 3.5E-16 2.8E-19 8.6E-16 5.7E-18 1.0E-16 1.3E-15

Water intake liters 1.6E+04 2.7E-02 3.3E+04 1.8E-01 6.2E-01 4.9E+04

Ozone depletion g CFC-11 eq 7.9E-08 9.6E-09 3.1E-07 5.3E-09 3.0E-07 7.0E-07


24

In addition to the impacts associated with the manufacturing stage of the product life cycle, examining the raw materials is important to understanding the life cycle of the products. This process includes quantifying all the material inputs including scrap rates. Each raw material has an associated environmental impact.

Titanium dioxide and the heat stabilizer are the most impactful materials on a mass basis. However, these materials are only small constituents in the overall product.

As shown in the inventory, Section 4.1 comprises the product formulation of the FRD products. These formulations were the basis for sections 6.2.1-6.2.3 which examines the environmental impacts of the three product formulations (per lb).

6.2 Raw Material Impacts

Table 6.3 Environmental Impacts of One lb Each of Raw Materials

Impact Category Unit Calcium Carbonate

Calcium Stearate

External Regrind

Impact Modifier- Arkema

Impact Modifier-

ElkemParaffin

Poly-ethylene

Wax

Internal Regrind

PVC Resin

PVC / Wood

RegrindStabilizer Titanium

DioxideParaffin

Wax

Global warming g CO2 eq 2.6E+00 9.8E+02 5.0E+01 3.0E+03 1.5E+03 3.4E+02 6.7E+02 9.2E+02 9.4E+02 1.1E+01 1.7E+03 3.4E+03 3.9E+02

Acidification H+ mmole eq 9.2E-01 3.0E+02 2.3E+01 8.5E+02 1.8E+03 1.3E+02 6.4E+02 5.3E+02 5.5E+02 4.5E+00 1.5E+03 1.1E+03 1.3E+02

HH cancer g C6H6 eq 2.2E-03 3.0E+00 3.0E-02 9.3E-01 1.2E+01 1.9E+00 9.5E-01 3.1E+00 3.0E+00 6.2E-03 7.6E+00 1.4E+01 1.2E+00

HH noncancer g C7H7 eq 3.3E+00 4.7E+03 4.5E+01 3.1E+03 2.1E+04 3.3E+03 3.0E+03 6.6E+03 5.9E+03 1.2E+01 5.3E+04 3.5E+04 1.8E+03

HH criteria air pollutants microDALYs 1.3E-03 1.8E-01 6.5E-03 2.5E-01 5.8E-01 4.6E-02 1.8E-01 1.7E-01 1.6E-01 1.1E-03 1.6E+00 5.3E-01 4.1E-02

Eutrophication g N eq 3.2E-04 7.1E+00 6.2E-03 2.5E+00 5.9E+00 6.8E-01 3.4E-01 2.1E+00 1.5E+00 2.3E-03 6.4E+00 2.5E+01 4.6E-01

Ecotoxicity g 2,4-D eq 7.6E-03 4.0E+00 1.1E-01 2.1E+00 1.8E+01 1.5E+00 3.6E+00 5.3E+00 4.8E+00 2.2E-02 8.3E+00 4.3E+01 1.4E+00

Smog g NOX eq 9.0E-03 4.9E+00 1.7E-01 7.0E+00 5.6E+00 1.5E+00 1.6E+00 2.3E+00 2.1E+00 5.4E-02 1.2E+01 1.2E+01 1.6E+00

Natural resource depletion MJ surplus 3.2E-03 6.7E-01 1.8E-02 7.3E+00 1.5E+00 3.2E+00 5.2E+00 2.9E+00 3.4E+00 8.9E-03 2.3E+00 3.1E+00 3.5E+00

Habitat alteration T&E count 0.0E+00 2.3E-14 0.0E+00 3.0E-15 3.6E-14 3.9E-15 9.6E-15 1.7E-14 1.6E-14 2.8E-18 5.3E-14 1.1E-13 1.5E-14

Water intake liters 0.0E+00 1.0E+03 0.0E+00 1.4E+02 5.7E+03 2.4E+02 4.6E+02 1.7E+03 1.6E+03 4.8E-01 3.8E+03 9.2E+03 3.0E+02

Ozone depletion g CFC-11 eq 8.5E-10 2.3E-05 5.0E-10 5.3E-06 4.5E-04 2.9E-06 5.2E-06 5.0E-04 6.0E-04 1.9E-09 4.4E-04 5.1E-04 1.3E-05

Figure 6.5 Relative Environmental Impacts of One lb Each of Raw Materials


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6.2.1 Bufftech Vinyl Fence Raw Materials

To investigate these raw material impacts further, Table 6.4 illustrates the environmental impact of each of the major raw materials used in the production of the vinyl fence products, in the proportions found in the average Bufftech product. In order to illustrate these impacts, the BEES impact methodology was used to assess the impacts of the raw materials in the proportions according to the recipe detailed in Table 4.1.

6.2 Raw Material Impacts (continued)

Table 6.4 Environmental Impact (BEES Methodology) Distribution of Vinyl Rail / Fence Formulation

Impact Category Unit PVC Resin Titanium Dioxide

Poly-ethylene

Wax

Calcium Stearate Paraffin Stabilizer


Calcium Carbonate


External Regrind Total

Global warming g CO2 eq 5.1E+02 5.5E+01 1.3E+00 7.9E+00 3.7E+00 1.2E+01 3.6E+01 1.9E-01 8.3E+00 1.6E+01 5.1E+02

Acidification H+ mmole eq 3.0E+02 1.8E+01 1.3E+00 2.4E+00 1.5E+00 1.0E+01 1.0E+01 6.8E-02 1.0E+01 7.2E+00 3.0E+02

HH cancer g C6H6 eq 1.6E+00 2.3E-01 1.9E-03 2.4E-02 2.1E-02 5.3E-02 1.1E-02 1.7E-04 6.9E-02 9.6E-03 1.6E+00

HH noncancer g C7H7 eq 3.2E+03 5.6E+02 6.1E+00 3.8E+01 3.6E+01 3.7E+02 3.7E+01 2.5E-01 1.2E+02 1.5E+01 3.2E+03

HH criteria air pollutants microDALYs 8.7E-02 8.5E-03 3.6E-04 1.4E-03 5.1E-04 1.1E-02 3.0E-03 9.7E-05 3.2E-03 2.1E-03 8.7E-02

Eutrophication g N eq 8.2E-01 4.0E-01 6.8E-04 5.7E-02 7.5E-03 4.5E-02 3.0E-02 2.4E-05 3.3E-02 2.0E-03 8.2E-01

Ecotoxicity g 2,4-D eq 2.6E+00 6.8E-01 7.2E-03 3.2E-02 1.6E-02 5.8E-02 2.5E-02 5.6E-04 1.0E-01 3.5E-02 2.6E+00

Smog g NOX eq 1.1E+00 1.9E-01 3.2E-03 3.9E-02 1.6E-02 8.2E-02 8.4E-02 6.6E-04 3.1E-02 5.4E-02 1.1E+00

Natural resource depletion MJ surplus 1.8E+00 5.0E-02 1.0E-02 5.3E-03 3.5E-02 1.6E-02 8.7E-02 2.4E-04 8.4E-03 5.6E-03 1.8E+00

Habitat alteration T&E count 8.7E-15 1.8E-15 1.9E-17 1.8E-16 4.3E-17 3.7E-16 3.7E-17 – 2.0E-16 – 8.7E-15

Water intake liters 9.0E+02 1.5E+02 9.2E-01 8.3E+00 2.7E+00 2.7E+01 1.7E+00 – 3.2E+01 – 9.0E+02

Ozone depletion g CFC-11 eq 3.3E-04 8.1E-06 1.0E-08 1.8E-07 3.1E-08 3.1E-06 6.4E-08 6.3E-11 2.5E-06 1.6E-10 3.3E-04


26

6.2.1 Bufftech Vinyl Fence Raw Materials (continued)

The PVC resin is the driver of environmental impacts in the raw materials stage of vinyl fence products. Titanium dioxide does have some impact on the raw materials stage of the fence as well. While external regrind is 32% of the formulation, this material has only a little impact on the overall raw materials stage. As regrind is recycled content, only the processing from the regrind supplier was considered; the upstream burdens and impacts from the PVC was excluded according to the cut-off methodology as the assumption is made that the first product will claim the burden of the production of PVC, and not the fence product.

6.2 Raw Material Impacts (continued)Figure 6.6 Relative Environmental Impact (BEES Methodology) Distribution of Vinyl Rail / Fence Formulation


27

6.2.2 Kingston Vinyl Rail Raw Materials

The PVC resin is the driver of environmental impacts in the raw materials stage of vinyl fence products. Titanium dioxide does have some impact on the raw materials stage of the fence as well.

6.2 Raw Material Impacts (continued)Figure 6.7 Relative Environmental Impact (BEES Methodology) Distribution of Kingston Rail Formulation


28

6.2.2 Kingston Vinyl Rail Raw Materials (continued)

Table 6.5 Environmental Impact (BEES Methodology) Distribution of Kingston Vinyl Rail Formulation (per lb)

Impact Category Unit (per lb) PVC Resin Titanium Dioxide

Poly-ethylene

Wax

Calcium Stearate Paraffin Stabilizer


Calcium Carbonate


External Regrind Total

Global warming g CO2 eq 5.1E+02 5.5E+01 1.3E+00 7.9E+00 3.7E+00 1.1E+01 3.6E+01 1.9E-01 8.3E+00 1.6E+01 6.5E+02

Acidification H+ mmole eq 3.0E+02 1.8E+01 1.3E+00 2.4E+00 1.5E+00 1.0E+01 1.0E+01 6.8E-02 1.0E+01 7.2E+00 3.6E+02

HH cancer g C6H6 eq 1.6E+00 2.3E-01 1.5E-03 2.4E-02 2.1E-02 5.1E-02 1.1E-02 1.7E-04 6.9E-02 9.6E-03 2.0E+00

HH noncancer g C7H7 eq 3.2E+03 5.6E+02 4.9E+00 3.8E+01 3.6E+01 3.6E+02 3.7E+01 2.5E-01 1.2E+02 1.5E+01 4.4E+03

HH criteria air pollutants microDALYs 8.7E-02 8.5E-03 2.9E-04 1.4E-03 5.1E-04 1.1E-02 3.0E-03 9.7E-05 3.2E-03 2.1E-03 1.2E-01

Eutrophication g N eq 8.2E-01 4.0E-01 5.4E-04 5.7E-02 7.5E-03 4.4E-02 3.0E-02 2.4E-05 3.3E-02 2.0E-03 1.4E-00

Ecotoxicity g 2,4-D eq 2.6E+00 6.8E-01 5.7E-03 3.2E-02 1.6E-02 5.6E-02 2.5E-02 5.6E-04 1.0E-01 3.5E-02 3.6E+00

Smog g NOX eq 1.1E+00 1.9E-01 2.6E-03 3.9E-02 1.6E-02 7.9E-02 8.4E-02 6.6E-04 3.1E-02 5.4E-02 1.6E+00

Natural resource depletion MJ surplus 1.8E+00 5.0E-02 8.4E-03 5.3E-03 3.5E-02 1.6E-02 8.7E-02 2.4E-04 8.4E-03 5.6E-03 2.0E+00

Habitat alteration T&E count 8.7E-15 1.8E-15 1.5E-17 1.8E-16 4.3E-17 3.6E-16 3.7E-17 — 2.0E-16 — 1.1E-14

Water intake liters 9.0E+02 1.5E+02 7.3E-01 8.3E+00 2.7E+00 2.6E+01 1.7E+00 — 3.2E+01 — 1.1E+03

Ozone depletion g CFC-11 eq 3.3E-04 8.1E-06 8.3E-09 1.8E-07 3.1E-08 3.0E-06 6.4E-08 6.3E-11 2.5E-06 1.6E-10 3.4E-04



29

6.2.3 Panorama Composite Rail Raw Materials

Table 6.6 and Figure 6.8 illustrate the relative environmental impact of each of the major raw materials used in the production of Panorama, in the proportions found in the average Panorama product. The PVC resin contributes the majority of the raw material impacts.

6.2 Raw Material Impacts (continued)Figure 6.8 Relative Environmental Impact (BEES Methodology) Distribution of Panorama Rail Formulation


30

6.2.3 Panorama Composite Rail Raw Materials (continued)


Table 6.6 Environmental Impact (BEES Methodology) Distribution of Panorama Rail Formulation (per lb)

Impact Category Unit (per lb) PVC / Wood Regrind PVC Resin Titanium

DioxidePolyethylene

WaxCalcium Stearate Paraffin Stabilizer Impact

Modifier-ArkemaCalcium

Carbonate Total

Global warming g CO2 eq 9.9E+00 7.7E+01 2.7E+01 1.1E-01 9.8E-01 3.7E-01 1.7E+00 7.2E+00 1.1E-02 1.2E+02

Acidification H+ mmole eq 4.1E+00 4.5E+01 9.1E+00 1.0E-01 3.0E-01 1.5E-01 1.5E+00 2.0E+00 3.9E-03 6.3E+01

HH cancer g C6H6 eq 5.6E-03 2.4E-01 1.1E-01 1.5E-04 3.0E-03 2.1E-03 7.6E-03 2.2E-03 9.6E-06 3.8E-01

HH noncancer g C7H7 eq 1.1E+01 4.9E+02 2.8E+02 4.9E-01 4.7E+00 3.6E+00 5.3E+01 7.4E+00 1.4E-02 8.5E+02

HH criteria air pollutants microDALYs 1.0E-03 1.3E-02 4.3E-03 2.9E-05 1.8E-04 5.1E-05 1.6E-03 6.0E-04 5.6E-06 2.1E-02

Eutrophication g N eq 2.1E-03 1.2E-01 2.0E-01 5.4E-05 7.1E-03 7.5E-04 6.4E-03 6.1E-03 1.4E-06 3.5E-01

Ecotoxicity g 2,4-D eq 2.0E-02 3.9E-01 3.4E-01 5.7E-04 4.0E-03 1.6E-03 8.3E-03 5.1E-03 3.2E-05 7.7E-01

Smog g NOX eq 4.8E-02 1.7E-01 9.3E-02 2.6E-04 4.9E-03 1.6E-03 1.2E-02 1.7E-02 3.9E-05 3.5E-01

Natural resource depletion MJ surplus 8.0E-03 2.7E-01 2.5E-02 8.4E-04 6.7E-04 3.5E-03 2.3E-03 1.7E-02 1.4E-05 3.3E-01

Habitat alteration T&E count 2.5E-18 1.3E-15 8.8E-16 1.5E-18 2.3E-17 4.3E-18 5.3E-17 7.3E-18 — 2.3E-15

Water intake liters 4.3E-01 1.4E+02 7.4E+01 7.3E-02 1.0E+00 2.7E-01 3.8E+00 3.5E-01 — 2.1E+02

Ozone depletion g CFC-11 eq 1.7E-09 4.9E-05 4.0E-06 8.3E-10 2.3E-08 3.1E-09 4.4E-07 1.3E-08 3.7E-12 5.4E-05


31

An average of 25 years is suggested as the likely life of most vinyl rail and composite rail products. Lifetime warranties are provided by CertainTeed for fence products, so a lifetime of 50 years can be assumed for vinyl fence. During the use phase, the products may be cleaned with soapy water, however, due to the high variability of cleaning this phase was excluded from the scope. No additional impacts are contributed by the use phase.

6.3.1 Bufftech Vinyl Fence Installation Materials

Hardware, footings, post caps and inserts are included in this life cycle assessment as all of these materials are required for the Bufftech fencing systems. Table 6.7 and Figure 6.9 show the results of the impact assessment of the installation materials recommended for the Chesterfield fencing product.

6.3 Installation and Use PhaseFigure 6.9 Bufftech Chesterfield Installation Materials (per 8ft section)

Table 6.7 Bufftech Chesterfield Installation Materials (per 8ft section)

Impact Category Unit PVC Posts and Post Caps Stainless Steel Hardware Concrete Footing Steel Inserts Total

Global warming g CO2 eq 1.6E+04 1.1E+03 9.9E+03 2.6E+04 5.4E+04

Acidification H+ mmole eq 9.7E+03 3.4E+02 2.7E+03 8.2E+03 2.1E+04

HH cancer g C6H6 eq 5.2E+01 4.2E+01 4.1E+01 1.0E+03 1.2E+03

HH noncancer g C7H7 eq 1.0E+05 2.5E+04 6.9E+04 6.1E+05 8.0E+05

HH criteria air pollutants microDALYs 2.8E+00 4.5E-01 1.1E+00 1.1E+01 1.5E+01

Eutrophication g N eq 2.6E+01 3.6E+00 1.2E+01 8.8E+01 1.3E+02

Ecotoxicity g 2,4-D eq 8.4E+01 1.4E+01 6.1E+01 3.5E+02 5.1E+02

Smog g NOX eq 3.7E+01 3.5E+00 4.5E+01 8.5E+01 1.7E+02

Natural resource depletion MJ surplus 5.9E+01 9.0E-01 8.3E+00 2.2E+01 9.0E+01

Habitat alteration T&E count 2.8E-13 8.3E-14 1.2E-13 2.0E-12 2.5E-12

Water intake liters 2.9E+04 2.5E+04 1.3E+04 6.0E+05 6.7E+05

Ozone depletion g CFC-11 eq 1.0E-02 1.5E-05 2.0E-04 3.6E-04 1.1E-02


32

6.3.1 Bufftech Vinyl Fence Installation Materials (continued)

For Chesterfield, the steel inserts are the main driver of the installation materials in most categories. Posts and caps (made from PVC) are a second driver of installing PVC fence, and are the primary driver in categories of global warming, acidification, natural resource depletion and ozone depletion.

Table 6.8 and Figure 6.10 show the results of the impact assessment of the installation materials recommended for New Lexington.

The results for New Lexington are very similar, since the amount of installation materials required are similar to that of Chesterfield. For both fence types, Chesterfield and New Lexington, steel inserts and PVC posts and caps

6.3 Installation and Use Phase (continued)

Table 6.8 Bufftech New Lexington Installation Materials (per 8ft section)

Impact Category Unit PVC Posts and Post Caps Stainless Steel Hardware Concrete Footing Steel Inserts Total

Global warming g CO2 eq 1.4E+04 1.1E+03 9.9E+03 2.8E+04 5.3E+04

Acidification H+ mmole eq 8.1E+03 3.4E+02 2.7E+03 8.9E+03 2.0E+04

HH cancer g C6H6 eq 4.3E+01 4.2E+01 4.1E+01 1.1E+03 1.2E+03

HH noncancer g C7H7 eq 8.6E+04 2.5E+04 6.9E+04 6.6E+05 8.4E+05

HH criteria air pollutants microDALYs 2.3E+00 4.5E-01 1.1E+00 1.2E+01 1.6E+01

Eutrophication g N eq 2.2E+01 3.6E+00 1.2E+01 9.5E+01 1.3E+02

Ecotoxicity g 2,4-D eq 6.9E+01 1.4E+01 6.1E+01 3.8E+02 5.2E+02

Smog g NOX eq 3.0E+01 3.5E+00 4.5E+01 9.2E+01 1.7E+02

Natural resource depletion MJ surplus 4.9E+01 9.0E-01 8.3E+00 2.4E+01 8.1E+01

Habitat alteration T&E count 2.3E-13 8.3E-14 1.2E-13 2.2E-12 2.6E-12

Water intake liters 2.4E+04 2.5E+04 1.3E+04 6.5E+05 7.1E+05

Ozone depletion g CFC-11 eq 8.7E-03 1.5E-05 2.0E-04 3.8E-04 9.3E-03

Figure 6.10 Bufftech New Lexington Installation Materials (per 8ft section)


33

6.3.1 Bufftech Vinyl Fence Installation Materials (continued)

are a large driver of installation materials. By incorporating recycled content into steel, or investigating other materials such as aluminum may help reduce the installation phase of the fence life cycle.

6.3.2 Kingston Vinyl Rail Installation Materials

Kingston rail requires aluminum inserts, post covers and caps and additional hardware for installation and use. These materials were included in the railing system in the installation stage of the product life cycle. Table 6.9 shows the potential environmental impact results of these materials for an eight foot section of railing.

Hardware is the dominant driver of the installation materials for the Kingston railing system for the human health impact categories (cancer, noncancer and criteria air pollutants) as well as eutrophication, ecotoxicity, habitat alteration and water intake. Posts and post caps drive global warming, acidification, natural resource depletion, and ozone depletion due to the upstream production of PVC resin used in the caps.


Table 6.9 Kingston Installation Materials (per 8ft section)

Impact Category Unit PVC Posts and Post Caps Stainless Steel Hardware Aluminum Inserts Total

Global warming g CO2 eq 4.5E+03 2.1E+03 3.0E+03 9.6E+03

Acidification H+ mmole eq 2.6E+03 6.7E+02 1.3E+03 4.6E+03

HH cancer g C6H6 eq 1.4E+01 8.4E+01 1.4E+00 9.9E+01

HH noncancer g C7H7 eq 2.8E+04 4.9E+04 2.6E+03 8.0E+04

HH criteria air pollutants microDALYs 7.6E-01 8.9E-01 4.7E+01 2.1E+00

Eutrophication g N eq 7.2E+00 7.1E+00 3.4E-01 1.5E+01

Ecotoxicity g 2,4-D eq 2.3E+01 2.8E+01 6.8E+00 5.8E+01

Smog g NOX eq 9.9E+00 6.9E+00 8.6E+00 2.5E+01

Natural resource depletion MJ surplus 1.6E+01 1.8E+00 3.7E+00 2.1E+01

Habitat alteration T&E count 7.6E-14 1.6E-13 – 2.4E-13

Water intake liters 7.8E+03 4.9E+04 – 5.7E+04

Ozone depletion g CFC-11 eq 2.8E-03 2.9E-05 4.2E-06 2.9E-03

Figure 6.11 Kingston Installation Materials (per 8ft section)


34

6.3.3 Panorama Composite Rail Installation Materials

Panorama requires post covers and caps and additional hardware for installation and use. These materials were included in the railing system in the installation stage of the product life cycle.

Hardware is the dominant driver of the installation materials for the composite railing system. Posts and post caps drive ozone depletion, due to the upstream production of PVC resin used in the caps.


Table 6.10 Panorama Rail Installation Materials (per 8ft section)

Impact Category Unit Posts and Post Caps Stainless Steel Hardware Total

Global warming g CO2 eq 1.9E+03 8.3E+03 1.0E+04

Acidification H+ mmole eq 1.0E+03 2.6E+03 3.6E+03

HH cancer g C6H6 eq 5.8E+00 3.2E+02 3.3E+02

HH noncancer g C7H7 eq 1.3E+04 1.9E+05 2.0E+05

HH criteria air pollutants microDALYs 3.2E-01 3.5E+00 3.8E+00

Eutrophication g N eq 4.6E+00 2.8E+01 3.2E+01

Ecotoxicity g 2,4-D eq 1.1E+01 1.1E+02 1.2E+02

Smog g NOX eq 4.9E+00 2.7E+01 3.2E+01

Natural resource depletion MJ surplus 5.6E+00 6.9E-00 1.2E+01

Habitat alteration T&E count 3.4E-14 6.4E-13 6.7E-13

Water intake liters 3.3E+03 1.9E+05 1.9E+05

Ozone depletion g CFC-11 eq 9.3E-04 1.1E-04 1.0E-03

Figure 6.12 Panorama Rail Installation Materials (per 8ft section)


35

6.4.1 Overall Energy and Carbon Life Cycle Impacts

Energy is consumed in raw materials extraction and processing, manufacturing, transportation, use phase, and final product disposal. The cumulative energy demand (CED) represents all the energy needed to convert a material to its final product. The values for cumulative energy demand for an eight foot section of Bufftech fence, Kingston rail and Panorama rail are listed in Table 6.5 and illustrated in Figure 6.13 and Figure 6.14.

6.4 Overall Environmental Impact

Table 6.11 Cumulative Energy Demand (CED) for Vinyl Fence, Vinyl Rail and Composite Rail (MJ / 8ft)

Bufftech® Chesterfield

Fence


Fence


Panorama®

Railing System

(MJ / 8ft) (MJ / 8ft) (MJ / 8ft) (MJ / 8ft)

Raw materials 1,185 888 510 125

Raw materials transportation 25 19 11 15

Manufacturing 128 96 52 79

Product shipping 37 28 97 147

Packaging 47 35 31 65

Installation 967 920 198 176

Waste disposal 59 44 39 37

Total 2,448 2,030 938 644


6.4.1 Overall Energy and Carbon Life Cycle Impacts (continued)

Raw materials drive the life cycle impacts for the cumulative energy demand of Bufftech fence and Kingston railing. Installation materials are a close second driver of Bufftech fence due to the steel inserts and concrete. As Panorama uses recycled content in the formulation which reduces impacts in that stage, installation materials are the primary drivers of the composite railing life cycle energy demand. Packaging has significant impacts on the overall life cycle for the railing products. The main driver of packaging is the lumber used for packaging – some lumber assumed for railing products is cut to size and drives the impacts.

Global warming potential (GWP) was also analyzed for the same life cycle stages. Similarly, the GWP results represent all the greenhouse gas emissions created in the extraction and conversion of the various raw materials through final disposal of the product. The values for GWP for an eight foot section of the fence and rail products are listed in Table 6.12 and illustrated in Figures 6.15 and 6.16.

36

6.4 Overall Environmental Impact (continued)Figure 6.13 Cumulative Energy Demand (CED) for the Life Cycle Stages of CertainTeed Bufftech Fence Systems (MJ / 8ft)

Figure 6.14 Cumulative Energy Demand (CED) for the Life Cycle Stages of Kingston and Panorama Railing Systems (MJ / 8ft)


37

6.4 Overall Environmental Impact (continued)

Table 6.12 Global Warming Potential (GWP) Values for Vinyl Fence, Vinyl Rail and Composite Rail (g CO2 eq / 8ft)

Bufftech® Chesterfield

Fence


Fence


Panorama®

Railing System

(g CO2 / 8ft) (g CO2 / 8ft) (g CO2 / 8ft) (g CO2 / 8ft)

Raw materials 45,933 34,425 19,755 5,487

Raw materials transportation 1,881 1,410 813 1,074

Manufacturing 701 525 285 232

Product shipping 1,435 1,075 3,344 4,953

Packaging 3,412 2,557 2,257 4,752

Installation 53,764 53,038 9,630 10,224

Waste disposal 3,815 2,860 3,520 2,385

Total 110,941 95,892 39,604 29,107

Figure 6.15 Global Warming Potential (GWP) for the Life Cycle Stages of BuffTech Fence (g CO2 eq / 8ft product)


38

6.4.1 Overall Energy and Carbon Life Cycle Impacts (continued)

Installation materials are the primary driver stage of the carbon footprint of Bufftech fence and Panorama composite rail while the raw materials are the driver stage of the Kingston rail. Panorama has a reduced carbon footprint in the raw materials stage from the integration of recycled content which is why the raw materials do not drive the overall life cycle for that product. Raw materials extraction and processing are the second largest life cycle stage for Bufftech fence.


Figure 6.16 Global Warming Potential (GWP) for the Life Cycle Stages of CertainTeed Railing Systems (g CO2 eq / 8ft)


39

6.4.2 Bufftech Overall Environmental Impacts

The graphs in this section are designed to communicate the overall environmental impacts of the fence and rail products using the BEES methodology. For more detail on the impact categories and the BEES methodology, see Section 5.2 above.

Table 6.13 and Figure 6.17 demonstrate the overall environmental impact (using the BEES methodology) of manufacturing an eight foot section of Bufftech Chesterfield vinyl fence. The figure illustrates the relative impact contribution from each of the seven life cycle stages (Raw Material Extraction and Processing, Raw Material Shipping, Manufacturing, Product Shipping, Packaging, Installation, and Final Disposal) to each of the environmental impacts. In this analysis, raw material transportation impacts are separated from the “Raw Material Extraction and Processing” stage to show the impacts of that transportation has on procurement.


Table 6.13 Bufftech Chesterfield Vinyl Fence Environmental Impacts per 8ft

Impact Category Unit (per 8ft) Raw Materials

Raw Material Transport Processing Packaging Final Product

Transport Installation End of Life Total

Global warming g CO2 eq 4.6E+04 1.9E+03 2.0E+03 1.4E+03 3.4E+03 5.4E+04 3.8E+03 1.1E+05

Acidification H+ mmole eq 2.6E+04 1.2E+03 2.1E+02 3.6E+02 1.1E+03 2.1E+04 1.2E+03 5.1E+04

HH cancer g C6H6 eq 1.4E+02 9.1E-01 4.9E+01 2.7E+00 1.5E+00 1.2E+03 9.6E+01 1.4E+03

HH noncancer g C7H7 eq 3.1E+05 2.8E+03 2.1E+05 4.2E+03 1.2E+03 8.0E+05 1.4E+05 1.3E+06

HH criteria air pollutants microDALYs 8.3E+00 1.6E-01 1.3E-01 1.9E-01 1.6E-01 1.5E+01 3.7E-01 2.5E+01

Eutrophication g N eq 9.9E+01 1.4E+00 6.4E+00 2.1E+00 1.1E+00 1.3E+02 3.6E+00 2.4E+02

Ecotoxicity g 2,4-D eq 2.5E+02 3.5E+00 9.8E+01 3.2E+00 4.4E+00 5.1E+02 3.1E+01 8.2E+02

Smog g NOX eq 1.1E+02 3.3E+01 4.6E+00 6.3E+00 2.8E+01 1.7E+02 3.1E+01 3.9E+02

Natural resource depletion MJ surplus 1.4E+02 3.4E+00 7.5E-01 4.4E+00 6.1E+00 9.0E+01 7.6E+00 2.6E+02

Habitat alteration T&E count 8.0E-13 1.5E-15 3.9E-14 1.3E-14 0.0E+00 2.5E-12 1.1E-12 4.4E-12

Water intake liters 7.9E+04 2.6E+02 1.1E+06 1.3E+03 0.0E+00 6.7E+05 1.3E+03 1.9E+06

Ozone depletion g CFC-11 eq 2.4E-02 9.8E-07 7.1E-05 2.7E-05 1.3E-07 1.1E+02 4.4E-04 3.6E-02


40

6.4.2 Bufftech Overall Environmental Impacts (continued)

Figure 6.17 shows that for vinyl fence, installation contributes a majority of the impact in most categories except for water intake. A significant portion of the installation impact is related to the steel inserts, as detailed in Section 6.3.1. For water intake, the majority occurs in the manufacturing stage. This intake is caused by the electricity generation from hydropower which consumes some water in the process of generating energy.

Table 6.14 and Figure 6.18 demonstrate the overall environmental impact (using the BEES methodology) of manufacturing one kilogram of the vinyl rail product. This figure illustrates the relative impact contribution from each of the seven life cycle stages (raw material extraction and processing, raw material shipping, manufacturing, packaging, product shipping, installation and final disposal) to each of the environmental impacts. In this analysis, raw material transportation impacts are separated from the “raw material extraction and processing” stage.


Figure 6.17 Environmental Impacts of Bufftech Chesterfield Vinyl Fence (BEES Impact Assessment Methodology)


41



Table 6.14 Bufftech New Lexington Vinyl Fence Environmental Impacts per 8ft









Eutrophication g N eq 7.4E+01 1.1E+00 4.8E+00 1.5E+00 8.2E-01 1.3E+02 2.7E+00 2.4E+02




Habitat alteration T&E count 6.0E-13 1.1E-15 2.9E-14 9.9E-15 0.0E+00 2.6E-12 8.4E-13 4.3E-12


Ozone depletion g CFC-11 eq 1.8E-02 7.3E-07 5.3E-05 2.0E-05 9.9E-08 9.3E-03 3.3E-04 3.6E-02


42



Figure 6.18 Environmental impacts of Bufftech New Lexington Vinyl Fence (BEES Impact Assessment Methodology)


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A comparison of the two product lines of BuffTech is shown below in Figure 6.19.

Chesterfield is generally higher in impacts compared to New Lexington. For the water intake and human health cancer categories, both product types are equivalent in impacts.


Figure 6.19 Overall Life Cycle Comparison of the New Lexington and Chesterfield Fence Lines


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6.4.3 Kingston Overall Environmental Impacts

Table 6.15 demonstrate the overall environmental impact (using the BEES methodology) of manufacturing eight feet of the Kingston vinyl railing system. This figure illustrates the relative impact contribution from each of the seven life cycle stages to each of the environmental impacts.


Table 6.15 Environmental Impacts of Kingston Vinyl Railing System (per 8ft)









Eutrophication g N eq 4.2E+01 6.1E-01 9.2E-01 6.4E+00 9.1E-01 1.5E+01 1.6E+02 2.2E+02




Habitat alteration T&E count 3.4E-13 6.4E-16 1.4E-14 7.2E-14 1.8E-15 2.4E-13 6.9E-13 1.4E-12




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6.4.3 Kingston Overall Environmental Impacts (continued)

Figure 6.20 illustrates the relative impacts of Table 6.15.


Figure 6.20 Environmental Impacts of Kingston Vinyl Railing System


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6.4.4 Panorama Overall Environmental Impacts

Table 6.16 and Figure 6.21 demonstrate the overall environmental impact (using the BEES methodology) of manufacturing eight feet of composite rail product. This figure illustrates the relative impact contribution from each of the seven life cycle stages to each of the environmental impacts.


Table 6.16 Environmental Impacts of Panorama Composite Railing System (per 8ft)








HH criteria air pollutants microDALYs 9.2E-01 5.7E-02 6.6E-02 7.1E-01 2.3E-01 3.8E+00 2.3E-01 6.0E+00

Eutrophication g N eq 1.5E+01 4.9E-01 9.5E-01 7.8E+00 1.9E+00 3.2E+01 2.3E+00 6.1E+01




Habitat alteration T&E count 1.0E-13 8.5E-16 2.0E-14 7.9E-14 3.7E-15 6.7E-13 7.0E-13 1.6E-12




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6.4.4 Panorama Overall Environmental Impacts (continue)

Installation is the main driver of impacts for the Panorama railing system in most impact categories except smog, natural resource depletion, water intake, and ozone depletion. Smog is driven by the transportation impacts during distribution. Processing drives water intake due to the hydropower used for energy generation.


Figure 6.21 Environmental Impacts of Panorama Composite Rail (BEES Impact Assessment Methodology)


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7.1 Hydropower Sensitivity AnalysisThe Buffalo facility has a power purchase agreement with the local hydropower facility which provides all electricity to the plant. Without this agreement, the Buffalo facility would be obtaining their electricity from the local electrical grid, NYPP. A sensitivity analysis was performed to show the difference between the two sources of electricity generation. Table 7.1 and Figure 7.1 show the difference between producing one pound of product using hydropower generated electricity compared to the local electricity grid.

7.0 Sensitivity Analyses

Table 7.1 Sensitivity Analysis on the Electricity Generation Source for the FRD Manufacturing Process (per lb of Product)

Impact Category Unit (per 8ft) Hydro eGrid

Global warming g CO2 eq 5.3E+00 1.7E+02

Acidification H+ mmole eq 1.3E+00 7.5E+01

HH cancer g C6H6 eq 3.9E+02 1.1E-01

HH noncancer g C7H7 eq 5.5E+01 1.5E+02

HH criteria air pollutants microDALYs 1.5E-03 2.1E-02

Eutrophication g N eq 2.2E-02 3.6E-02

Ecotoxicity g 2,4-D eq 5.6E-02 3.5E-01

Smog g NOX eq 2.6E-02 4.7E-01

Natural resource depletion MJ surplus 6.3E-03 1.9E-01

Habitat alteration T&E count 4.5E-16 1.1E-16

Water intake liters 1.6E+04 3.1E+00

Ozone depletion g CFC-11 eq 6.3E-07 5.5E-07

Figure 7.1 Sensitivity Analysis on the Electricity Generation Source for the FRD Manufacturing Process


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Hydropower has less of a potential environmental impact during the production of fence and railing products than using the local grid except for the categories habitat alteration, water intake and ozone depletion. Acidification is the impact category with the most reductions of 96% while eutrophication is only reduced by 33%. Water intake greatly increases as water is required for the generation of hydropower; however, it is important to note that most of the input water will not be consumed in the turbines but will be returned to the watershed.

Since production is only a small part of the life cycle of each of these products, analyses were also conducted for the overall life cycle of both the Kingston and the Panorama Railing systems to show the effect of this purchased power agreement.

7.1 Hydropower Sensitivity Analysis (continued)

Table 7.2 Sensitivity Analysis on the Electricity Generation Source for the Life Cycle of CertainTeed Railing Systems

Impact Category Unit Kingston Panorama

BEES v4.04+ (per 8ft) Hydro eGrid Hydro eGrid

Global warming g CO2 eq 4.0E+04 4.4E+04 2.9E+04 3.6E+04

Acidification H+ mmole eq 1.9E+04 2.1E+04 1.1E+04 1.4E+04

HH cancer g C6H6 eq 2.1E+02 2.1E+02 4.2E+02 4.3E+02

HH noncancer g C7H7 eq 6.5E+05 6.5E+05 3.7E+05 3.7E+05

HH criteria air pollutants microDALYs 6.6E+00 7.2E+00 6.0E+00 6.9E+00

Eutrophication g N eq 2.2E+02 2.2E+02 6.1E+01 6.2E+01

Ecotoxicity g 2,4-D eq 3.6E+02 3.7E+02 2.0E+02 2.2E+02

Smog g NOX eq 1.4E+02 1.6E+02 1.4E+02 1.6E+02

Natural resource depletion MJ surplus 1.0E+02 1.1E+02 5.4E+01 6.2E+01

Habitat alteration T&E count 1.4E-12 1.4E-12 1.6E-12 1.6E-12

Water intake liters 5.6E+05 9.6E+04 9.3E+05 2.1E+05

Ozone depletion g CFC-11 eq 1.4E-02 1.4E-02 3.8E-03 3.8E-03


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The potential of ozone depletion, eutrophication, ecotoxicity and human health (cancer and noncancer) from the Kingston product are not significantly influenced by the electricity source for the extrusion of these products. However, global warming, acidification, criteria air pollutants, smog and natural resource depletion decrease between 6% (natural resource depletion) to 12% (global warming and acidification) in the overall life cycle results.


Figure 7.2 Sensitivity Analysis on the Electricity Generation Source for the Life Cycle of the Kingston Railing System


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The potential of ozone depletion, habitat alteration, eutrophication and human health (cancer and noncancer) from the railing products are not significantly influenced by the electricity source for the extrusion of these products. However, global warming, acidification, criteria air pollutants, ecotoxicity, smog and natural resource depletion decrease more than 6% (ecotoxicity) to 24% (acidification) in the overall Panorama life cycle results. Water intake significantly increases by 77%; however, this water is not consumed in the generation of electricity, which, providing an analysis on water consumption and not just water intake would be much lower.


Figure 7.3 Sensitivity Analysis on the Electricity Generation Source for the Life Cycle of the Panorama Railing System


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CertainTeed integrates external regrind into the vinyl products produced at the Buffalo facility. This recycled content decreases the environmental impacts of the life cycle of the products. To show an example of the reduced impacts, a sensitivity was performed on the formulation of the Bufftech products. The external regrind was removed from the formulation. Table 7.3 shows the environmental impacts of a 100% virgin fence product.

7.2 Recycled Content Sensitivity Analysis

Table 7.3 Overall Life Cycle Environmental Impacts of BuffTech Chesterfield Fence with and without Recycled Content

Bufftech Chesterfield Fence

Impact Category Unit Current Formulation (32% Recycled Content)

Formulation with No Recycled Content

Global warming g CO2 eq 1.1E+05 1.3E+05

Acidification H+ mmole eq 5.1E+04 6.2E+04

HH cancer g C6H6 eq 1.4E+03 1.5E+03

HH noncancer g C7H7 eq 1.3E+06 1.4E+06

HH criteria air pollutants microDALYs 2.5E+01 2.8E+01

Eutrophication g N eq 2.4E+02 2.9E+02

Ecotoxicity g 2,4-D eq 8.2E+02 9.3E+02

Smog g NOX eq 3.9E+02 4.3E+02

Natural resource depletion MJ surplus 2.6E+02 3.2E+02

Indoor air quality g TVOC eq 0.0E+00 0.0E+00

Habitat alteration T&E count 4.4E-12 4.8E-12

Water intake liters 1.9E+06 1.9E+06

Ozone depletion g CFC-11 eq 3.6E-02 4.7E-02


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By incorporating recycled content into the fence and railing formulations, the overall life cycle impacts are reduced between 2% (in water intake) to 24% (in ozone depletion). CertainTeed should continue to integrate recycled content into these products to continue reducing the overall life cycle of the FRD products.

7.2 Recycled Content Sensitivity Analysis (continued)

Figure 7.4 Relative Overall Life Cycle Environmental Impacts of Bufftech Chesterfield Fence with and without Recycled Content


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This LCA is for internal use and will soon be published in the BEES online system. The study was conducted following appropriate ISO standards and best practices and is intended to assist CertainTeed with understanding the life cycle impacts of their products.

The inventory has been submitted to NIST for publication in the BEES online tool, and will undergo a review during that process. Since the BEES personnel will model the inventory independently in their own software tool, the exact results published in the BEES tool may vary from the results shown in this report.

The results of an LCA are inherently limited by the fact that characterized environmental impacts are “potential” impacts, and not a prediction of real impacts. Actual impacts will occur based on many variables of the system and nature, and can change in real time.

All data for the operation of the Buffalo plant, as well as transportation distances and modes, was collected directly from CertainTeed. Efforts were made to check the data for internal consistency and to verify data with plant personnel. Sub-metering of energy use for each critical stage in the manufacturing process would allow for more detailed analysis and is recommended.

The findings in this research are limited by the inherent uncertainty of creating a representative model through LCA. Many assumptions were made in modeling the product system with representative processes and datasets. The authors addressed the uncertainty in modeling decisions by conducting a mass balance and sensitivity analysis as the LCI model was being constructed (data verification/validation relative to cut-off criteria and study goals).

Further limitation exists due to the use of proxy materials for the composite material and the allocation methodology. All of these represent reasonably accurate approximations, but not exact amounts.

While quality control was undertaken at each step in building the LCI and conducting the LCIA, uncertainty is still present in the results since the data evaluated represents only one year of manufacturing information. Detailed evaluation of multiple manufacturing plants and time periods would reduce the uncertainty. Some level of uncertainty is inherent in conducting LCA and decision making must reflect this fact.

8.0 Limitations


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Based on the results from the life cycle assessment, the life cycle impacts for Bufftech and Panorama are driven by the installation materials; raw materials are the main driver for the Kingston railing system and a second close driver for Bufftech and Panorama. The reduction in electricity impacts from the purchase of hydropower generated power reduces the overall impacts of global warming, acidification, criteria air pollutants, ecotoxicity, smog, and natural resource depletion. Installation material impacts can be reduced by integrating more recycled content or using aluminum instead of steel and implementing supplier sustainability requirements.. Identifying alternate uses or recycling options of the vinyl and composite products will reduce the end-of-life impacts.

CertainTeed has direct control over the modes of transportation for raw materials and final products, as well as the manufacturing process. Any opportunities to reduce energy consumption in these areas will have a direct reduction in environmental impacts. It will also provide cost savings and potential competitive advantage.

The composite rail has clear advantages in raw materials as the core material contains higher recycled content compared to the other products evaluated in this study. External regrind is also a recycled material and should continue to be used in the Bufftech fence and Kingston rail products. CertainTeed should evaluate the possibility of increasing the amount of material, without compromising the performance of the products. These factors contribute to overall decreased impacts in most impact categories for railing systems.

9.0 Conclusions

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