ENVIRONMENTAL PRODUCT DECLARATION - Vallourec · /DIN 18800/ to /DIN 18808/: ... 4 Environmental...

Umwelt Produktdeklaration Name des Herstellers – Name des Produkts

ENVIRONMENTAL PRODUCT DECLARATIONas per ISO 14025 and EN 15804

Owner of the Declaration Vallourec Deutschland GmbHProgramme holder Institut Bauen und Umwelt e.V. (IBU)

Publisher Institut Bauen und Umwelt e.V. (IBU)

Declaration number EPD-VAL-20150248-IBB1-EN

Issue date 29.09.2015

Valid to 21.09.2020

Circular, square and rectangular structural hollow sectionsVallourec Deutschland GmbH

www.bau-umwelt.com / https://epd-online.com

2 Environmental Product Declaration VALLOUREC Deutschland GmbH – MSH Profiles

1. General Information

Vallourec Deutschland GmbH MSH-ProfileProgramme holderIBU - Institut Bauen und Umwelt e.V.Panoramastr. 110178 BerlinGermany

Owner of the DeclarationVallourec Deutschland GmbHTheodorstraße 10940472 DüsseldorfDeutschland

Declaration numberEPD-VAL-20150248-IBB1-EN

Declared product / Declared unitThe declaration refers to the production of 1 tonne structural hollow sections (MSH).

This Declaration is based on the Product Category Rules:Structural steels, 07.2014 (PCR tested and approved by the SVR)

Issue date29.09.2015

Valid to21.09.2020

Scope:This Environmental Product Declaration considers hot-finished MSH sections with circular, square and rectangular cross-sections manufactured in the Vallourec plants in Düsseldorf Rath and Mülheim (Germany). This document is translated from the German Environmental Product Declaration into English. It is based on the German original version EPD-VAL-20150248-IBB1-DE. The verifier has no influence on the quality of the translation.The owner of the declaration shall be liable for the underlying information and evidence; the IBU shall not be liable with respect to manufacturer information, life cycle assessment data and evidences.Verification

The CEN Norm /EN 15804/ serves as the core PCRIndependent verification of the declaration

according to /ISO 14025/Prof. Dr.-Ing. Horst J. Bossenmayer(President of Institut Bauen und Umwelt e.V.) internally x externally

Dr. Burkhart Lehmann(Managing Director IBU)

Dr. Frank Werner(Independent verifier appointed by SVR)

2. Product

2.1 Product descriptionMSH (hot-finished structural hollow) sections are hot-finished hollow sections for structural steel which are manufactured from non-alloy structural steels and fine-grain steels in accordance with /DIN EN 10 210-/1.2.2 ApplicationMSH sections are used in numerous construction applications:· Industrial buildings and halls· Bridge construction· Boiler support structures· Sports facilities (stadiums)· Exhibition buildings· Airport terminals and hangars· Steel-glass façades· Offshore constructions

2.3 Technical DataThe mechanical and technical properties displayed by hot-finished hollow sections are indicated in Part 1, Table A.3 (Non-alloy structural steels) and Table B.3 (Fine-grain steels) of the /DIN EN 10210/ delivery standard.Technical construction dataName Value Unit

Density 7850 kg/m3

Modulus of elasticity 210000 N/mm2

Coefficient of thermal expansion 11.5 - 11.9 10-6K-1

Thermal conductivity 35 - 47 W/(mK)Melting point depending on steel grade of up to 1538 °C

Electrical conductivity at 20°C depending on steel grade 3.8 - 4 Ω-1m-1

Minimum yield strength depending on steel grade 235 - 460 N/mm2

Minimum tensile strength depending on steel grade 360 - 720 N/mm2

2.4 Placing on the market / Application rulesDirective (EU) No. 305/2011 applies for placing the product on the market in the EU/EFTA (with the exception of Switzerland). The products require a Declaration of Performance considering /DIN EN 10 210/: Hot-finished structural hollow sections of non-alloy and fine-grain steelsPart 1: Technical delivery conditionsPart 2: Tolerances, dimensions and sectional properties


Application of the products is subject to the respective national guidelines; in Germany: ● /DIN 18800/ to /DIN 18808/: German application standards for steel construction ● /Eurocode 3/: /DIN EN 1993-1-1/ to /EN 1993-1-12/ European application standards for steel construction ● /DASt guidelines/: Supplementary guidelines, published by Deutscher Ausschuss für Stahlbau (DASt)

2.5 Delivery statusMSH sections are manufactured in one of the following delivery states:Grades JR, J0, J2 and K2: hot-finishedGrades N and NL: normalised, whereby normalising includes normalised rolling

2.6 Base materials / Ancillary materials The base material for manufacturing continuous casting as a preliminary material for MSH sections is iron (percentage by mass <= 99.5%). Other primary components are carbon, silicon and manganese. Chemical composition varies depending on the type of steel. The detailed percentages by mass are indicated in Part 1 of the /DIN EN10210/ product standard. Auxiliaries:Various lubricants depending on the respective rolling process 2.7 Manufacture1. Plug rolling mill in Düsseldorf RathAfter heating the continuous-cast circular steel blocks to approx. 1,280 °C in the rotary hearth furnace, the blocks are rolled out as hollow blocks in the cross rolling mill. The wall thickness of these hollow blocks is then reduced in two runs (stubs) in the plug rolling mill, whereby plugs and rolls form an annular gap. Reeling (straightening) and renewed heating in the reheating furnace is followed by final forming to the finished size on the sizing mill, whereby square and rectangular hollow sections are formed in the last stands. The MSH sections are then left to cool on the cooling bed before being directed along roller beds to the finishing section. 2. Mandrel rolling mill in MülheimFirst of all, the continuous-cast round bars are heated to rolling temperature in the rotary hearth furnace. This is followed by forming as hollow blocks in the cross rolling mill where two work rolls featuring special profiles rotate in the same direction and whose axes are inclined towards the horizontal stock axis. This generates a helical movement on the part of the stock across an internal tool acting as a piercer plug. The hollow block is rolled at a consistent heat over eight dual stands arranged in a close in-line formation, whereby the hollow block is slid onto a mandrel bar serving as an internal tool during rolling. The ensuing tube is reheated in a walking beam furnace before reshaping to the exact final circular, square or rectangular dimensions in the stretch-reducing mill. The MSH sections are then left to cool on the cooling bed before being directed along roller beds and by crane to the finishing section.

2.8 Environment and health during manufacturing

No particular environmental protection measures are necessary during manufacturing other than those specified by law. During the entire manufacturing process, no other health protection measures are required extending beyond the legally specified industrial protection measures for commercial enterprises. Certification of industrial safety and health protection in accordance with /OHSAS 18001/ is in place for the Vallourec sites indicated in 2.7.

2.9 Product processing/Installation Processing recommendations: Hot- and cold-formingHot- and cold-forming are possible without any difficulty. Hot-forming should be carried out in a range of 1,050 to 750 °C. Forming steps largely involving compression, e.g. forging, can be carried out in the upper temperature range while the lower temperature range should be used for those involving stretching. The temperature can decrease to 700 °C for degrees of deformation of less than 5% in the final stage. This must be followed by cooling down in stationary air. After hot-forming, normalising is necessary if temperatures arose outside the temperature range of 980 to 850 °C during the previous forming process. After stronger cold-forming processes requiring heat treatment in accordance with the respective guidelines (AD data sheets), stress-relief heat treatment is often sufficient unless other acceptance test procedures or other specifications expressly demand normalising. WeldingThe steels can be welded manually or automatically after each of these procedures. At external temperatures below approx. +5 °C and wall thicknesses exceeding 50 mm (for S 355 and higher exceeding 30 mm), preheating a sufficiently wide zone to 80 to 200 °C is recommended. In any case, the surface should be free of condensation. Stress-relief heat treatment (see heat treatment) is not generally necessary. It should only be carried out if demanded by a building regulation or when welded constructions and/or operating conditions commend depletion of the internal welding stresses. Verifiably suitable welding additives must be used for arc welding while alkaline welding additives are preferable for S 355 and higher. Industrial safety and health protection measures:No health protection measures over and beyond the standard industrial safety measures (e.g. protective gloves) are required during processing/installing the MSH sections. Environmental protection measures:No noteworthy environmental pollution is triggered by processing/assembling the products in question. No special measures need to be taken to protect the environment. Residual material incurred:Residual material and packaging incurred on the building site must be collected separately. The specifications of local waste authorities must be maintained during processing.


2.10 PackagingMSH sections (angular or circular) are bundled using steel bands and/or shipped on wooden beams, secured with wooden wedges (waste code nos.: 150103 packaging made of wood, 150104 packaging made of metal). All packaging can be re-used.

2.11 Condition of use Contents in condition of use:The material composition during the use phase is the same as at the time of production. MSH sections are manufactured from non-alloy structural steels and fine-grain structural steels in accordance with /DIN EN 10 210-1/. Contents are listed in Table 2.1 in section 2.Corrosion protection:Detailed information on corrosion protection is provided in Technical Information 4 “Corrosion protection of MSH sections” (available on the Vallourec Web site).

2.12 Environment and health during useGeneral health and environmental aspects:There are no health risks for users of MSH sections or for persons manufacturing or processing MSH sections. From an environmental perspective, there are no restrictions governing the use of MSH sections.

2.13 Reference service lifeBuilding product life cycles are dependent on the respective building design, use and maintenance. The use phase for structural hollow sections is not depicted as they involve maintenance-free and generally durable products.

2.14 Extraordinary effects

Fire

MSH sections comply with the requirements of construction product class A1 “non-flammable” in accordance with /DIN 4102, Part 1/ and /DIN EN 13501-1/. No smoke gas develops. Fire protectionName ValueBuilding material class A1

WaterThe effects of flooding on MSH sections do not lead to any changes in the product or any other negative environmental impact.

Mechanical destructionIn the event of extraordinary mechanical impact, steel structures display very good characteristics thanks to the high degree of ductility (malleability) of the material. As a general rule, no chips, breaking edges or similar are displayed.

2.15 Re-use phaseMSH sections are 100% recyclable. The MSH sections used in a structure are only partially re-used after demolition; the largest share is primarily directed to electro-steel plants as scrap.

2.16 DisposalAs steel is 100% recyclable, this material does not require disposal.Waste code in accordance with the European List of Wastes (EWC), as per the European List of Wastes Ordinance /AVV/: 17 04 05 Iron and steel.

2.17 Further informationMore information on MSH sections:www.vallourec.com

3. LCA: Calculation rules

3.1 Declared UnitThis declaration refers to the manufacture of 1 tonne structural hollow sections.

Declared unitName Value UnitDeclared unit 1 tThickness (for all hollow sections to) 120 mm

Density 7850 kg/m3

Conversion factor to 1 kg 0.001 -

3.2 System boundaryType of EPD: cradle to gate – with options The following life cycle phases are considered:

Product stage (Modules A1-A3)

Waste processing (Module C3)

Benefits and loads beyond the system boundaries (Module D)

The production stage considers: Provision of raw materials (steel billet),

auxiliaries and energy Transporting raw materials

Manufacturing process in the plant including energy, manufacturing auxiliaries, disposing of any residual materials incurred and consideration of plant emissions

Waste processing as well as benefits and loads beyond the system boundary:It is assumed for steel scrap that the waste characteristic ends after sorting and collecting following demolition.Module D considers the re-use and recycling of MSH sections.

3.3 Estimates and assumptionsFine-grain steels (low-alloy steels) are used for manufacturing MSH sections. These alloys are approximated by an average/generic data set /GaBi/.

3.4 Cut-off criteriaPackaging and its reuse is not considered in this study on account of its subordinate significance. Furthermore, landfilling of 1% loss is ignored in the End-of-Life phase.All data from the operating data survey is considered, i.e. all starting materials used, the thermal and electrical energy used. Accordingly, material and


energy flows with a share of less than 1 per cent were also considered.The total material and energy volumes ignored account for just under 5% in accordance with mass, energy or environmental relevance.

3.5 Background data“GaBi ts” – the software system for comprehensive analysis developed by thinkstep AG – was used for modelling the life cycle of the product under review. The data required for the upstream chain for which no specific details are available, is taken from the GaBi data base /GaBi ts/.

3.6 Data qualityThe primary data collated at the manufacturer’s is based on annual volumes and/or extrapolations from measurements at specific plants. Manufacturing data represents production year 2008. This was examined for representativity in 2014.Data sets are available in the GaBi data base /GaBi ts/ for the basic materials used. The data base was last updated in 2014.

3.7 Period under reviewAverages are formed on the basis of volumes sold in 2014.

3.8 AllocationThe requisite scrap is saturated during primary production of steel in order to determine the net scrap volume (input volume, Module D). Furthermore, a theoretically 100% primary steel route is calculated which is then offset against the expenses associated

with re-melting the scrap in the arc furnace. Please also refer to worldsteel /worldsteel 2011/.No production waste of relevance is incurred for direction to thermal recycling. Packaging materials fall short of the cut-off criteria and are not therefore considered in the LCA.Rolling produces mill scale which is re-used in the blast furnace for manufacturing the sinter. Mill scale makes a very low contribution to operating income which means it can be ignored. The environmental impacts are therefore allocated fully to the product and not to the mill scale. Accordingly, this represents a conservative scenario.The allocation method for co-products based on the steel billet data set (upstream process) is based on the allocation instructions in in EN ISO 14044:2006 and pursues the worldsteel method /worldsteel 2011/, which is in turn based on system expansion for co-products. The data set does not therefore correspond with the allocation principles outlined in EN 15804.A sensitivity analysis has shown that the differences in LCA results when applying an allocation based on physical properties (see /Eurofer 2013/) are around 3% in terms of the global warming potential and account for up to 15% in terms of the other impact categories. Use of the data set overestimates the environmental impact of iron extraction, thereby depicting a conservative approach.

3.9 ComparabilityBasically, a comparison or an evaluation of EPD data is only possible if all the data sets to be compared were created according to /EN 15804/ and the building context, respectively the product-specific characteristics of performance, are taken into account.

4. LCA: Scenarios and additional technical information

Re-use, recovery and recycling potential (D), relevant scenario informationName Value UnitCollection rate 100 %Recycling 88 %Re-use 11 %Loss 1 %


5. LCA: Results

DESCRIPTION OF THE SYSTEM BOUNDARY (X = INCLUDED IN LCA; MND = MODULE NOT DECLARED)

PRODUCT STAGECONSTRUCTION PROCESS

STAGEUSE STAGE END OF LIFE STAGE

BENEFITS AND LOADS

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A1 A2 A3 A4 A5 B1 B2 B3 B4 B5 B6 B7 C1 C2 C3 C4 D

X X X MND MND MND MND MND MND MND MND MND MND MND X MND X

RESULTS OF THE LCA - ENVIRONMENTAL IMPACT: 1 tonne structural hollow sectionsParameter Unit A1-A3 C3 D

Global warming potential [kg CO2-Eq.] 2.61E+3 0.00E+0 -1.68E+3Depletion potential of the stratospheric ozone layer [kg CFC11-Eq.] 2.72E-8 0.00E+0 1.25E-8

Acidification potential of land and water [kg SO2-Eq.] 8.32E+0 0.00E+0 -6.35E+0Eutrophication potential [kg (PO4)3--Eq.] 7.29E-1 0.00E+0 -5.36E-1

Formation potential of tropospheric ozone photochemical oxidants [kg ethene-Eq.] 1.16E+0 0.00E+0 -9.34E-1Abiotic depletion potential for non-fossil resources [kg Sb-Eq.] 6.05E-4 0.00E+0 -8.07E-5

Abiotic depletion potential for fossil resources [MJ] 2.62E+4 0.00E+0 -1.59E+4RESULTS OF THE LCA - RESOURCE USE: 1 tonne structural hollow sections

Parameter Unit A1-A3 C3 D

Renewable primary energy as energy carrier [MJ] 1.23E+3 0.00E+0 2.81E+2Renewable primary energy resources as material utilization [MJ] 0.00E+0 0.00E+0 0.00E+0

Total use of renewable primary energy resources [MJ] 1.23E+3 0.00E+0 2.81E+2Non-renewable primary energy as energy carrier [MJ] 2.70E+4 0.00E+0 -1.53E+4

Non-renewable primary energy as material utilization [MJ] 0.00E+0 0.00E+0 0.00E+0Total use of non-renewable primary energy resources [MJ] 2.70E+4 0.00E+0 -1.53E+4

Use of secondary material [kg] 1.72E+2 0.00E+0 9.30E+2Use of renewable secondary fuels [MJ] 0.00E+0 0.00E+0 0.00E+0

Use of non-renewable secondary fuels [MJ] 0.00E+0 0.00E+0 0.00E+0Use of net fresh water [m³] 2.27E+0 0.00E+0 -1.14E+0

RESULTS OF THE LCA – OUTPUT FLOWS AND WASTE CATEGORIES: 1 tonne structural hollow sections

Parameter Unit A1-A3 C3 D

Hazardous waste disposed [kg] 6.63E-2 0.00E+0 -5.40E-3Non-hazardous waste disposed [kg] 2.93E+1 0.00E+0 -2.34E+1

Radioactive waste disposed [kg] 3.08E-1 0.00E+0 2.41E-1Components for re-use [kg] 0.00E+0 0.00E+0 0.00E+0Materials for recycling [kg] 0.00E+0 9.90E+2 0.00E+0

Materials for energy recovery [kg] 0.00E+0 0.00E+0 0.00E+0Exported electrical energy [MJ] 0.00E+0 0.00E+0 0.00E+0Exported thermal energy [MJ] 0.00E+0 0.00E+0 0.00E+0

6. LCA: Interpretation

The interpretation considers all approximations and estimates as well as the cut-off criteria outlined in section 3.4.The GWP (global warming potential) is dominated by the raw material supply (Module A1).The GWP value in Module D represents the total loads and benefits outside the system boundary. During this life cycle phase, the loads representing the expenses associated with re-melting the steel scrap in the electric arc furnace and the benefits are attributable to the fact that the production of primary steel in the blast furnace is avoided.A detailed analysis of the environmental impact during the product stage is depicted in the following graphic.

A large share of the impact categories is dominated by steel manufacture. In terms of ADPe (abiotic depletion of resources elementary), the use of sodium chloride in waste processing plays a significant role.


As for ODP (ozone depletion potential), the electricity used for generating compressed air in production makes a significant contribution.

The use of thermal energy from natural gas, diesel, auxiliaries, transport and process-specific emissions only have a minor influence on environmental impact.

7. Requisite evidence

This EPD concerns semi-finished products made from structural steel. Further processing depends on the respective application. Accordingly, further documentation is not of relevance here.

7.1 WeatheringComponents manufactured from hollow sections are not generally exposed to weathering without protection. Corrosion protection systems are selected in accordance with the respective application and site.

8. References

Institut Bauen und UmweltInstitut Bauen und Umwelt e.V., Berlin(pub.):Generation of Environmental Product Declarations (EPDs);

General principlesfor the EPD range of Institut Bauen und Umwelt e.V. (IBU), 2013/04www.bau-umwelt.de

ISO 14025DIN EN ISO 14025:2011-10: Environmental labels and declarations — Type III environmental declarations — Principles and procedures

EN 15804EN 15804:2012-04+A1 2013: Sustainability of construction works — Environmental Product Declarations — Core rules for the product category of construction products

Product Category Rules for Construction Products, Part B: Requirements on the EPD for structural steels PCR instructions for building-related products and services in the construction product group of structural steels, Institut Bauen und Umwelt e.V., www.bau-umwelt.com, 2014-07GaBi tsGaBi ts dataset documentation for the software-system and databases, LBP, University of Stuttgart and thinkstep, Leinfelden-Echterdingen, 2014 (http://documentation.gabi-software.com/)

European Comission Technical Steel ResearchECSC project: LCA for steel construction – Final report EUR 20570 EN; February 2002; The Steel Construction Institute

Declaration Poutrelle en acierDeclaration Envrionnementale et Sanitaire, conforme a la norme NF P 01-010, Poutrelle en acier, Decembre 2007; Office Technique pour l’Utilastion de l’Acier

Steel RecyclingSteel recycling rates at a glance, 2007 Steel recycling rates; Steel Recycling Institute

Worldsteel 2011World Steel Association, Life cycle assessment (LCA) methodology report, Belgium, 14 Oct 2011

DIN EN 10210Hot-finished structural hollow sections of non-alloy and fine-grain steelsPart 1: Technical conditions for delivery, German version EN 10 210-1:2006Part 2: Tolerances, dimensions and sectional properties; German version EN 10 210-2:2006 DIN EN 13501-1DIN EN 13501-1:2010-01, Classification of Building Products and Methods by Fire Performance – Part 1: Classification with the results of tests on fire performance by building products; German version EN 13501-1:2007 DIN 4102-1DIN 4102-1:1998-05, Fire behaviour of building materials and building components – Part 1: Building materials, concepts, requirements and tests DIN 18800 to DIN 18808German application standards for steel construction Eurocode 3DIN EN 1993-1-1 to DIN EN 1993-1-12: European application standards for steel construction DASt guidelinesSupplementary guidelines, published by Deutscher Ausschuss für Stahlbau (DASt) OHSAS 18001OHSAS 18001:2007-07-31: Industrial safety management systems Requirements AVVOrdinance on the list of wastes (Directive governing the European Waste Index): 10 December 2001 (Federal Law Gazette No. I, p. 3379), last amended by Article 5, section 22 of the law dated 24 February 2012 (Federal Law Gazette No. I, p. 212)

DIN EN ISO 14044DIN EN ISO 14044:2006-10: Environmental Management – Life cycle assessment – Requirements and instructions (ISO 14044:2006) Worldsteel Association, EUROFER 2013Bollen, J., Avery N., Millar, I. and Broadbent, C.: Methodology to determine the LCI of steel industry co-products, 2013

http://www.bau-umwelt.de

PublisherInstitut Bauen und Umwelt e.V.Panoramastr. 110178 BerlinGermany

Tel +49 (0)30 3087748- 0Fax +49 (0)30 3087748- 29Mail [email protected] www.bau-umwelt.com

Programme holderInstitut Bauen und Umwelt e.V.Panoramastr 110178 BerlinGermany

Tel +49 (0)30 - 3087748- 0Fax +49 (0)30 – 3087748 - 29Mail [email protected] www.bau-umwelt.com

Author of the Life Cycle Assessmentthinkstep AGHauptstraße 111-170771 Leinfelden-EchterdingenGermany

Tel +49 711 341817-0Fax +49 711 341817-25Mail [email protected] www.thinkstep.com

Owner of the DeclarationVallourec Deutschland GmbHTheodorstraße 10940472 DüsseldorfGermany

Tel +49 211 960-0Fax +49 211 960-3995Mail [email protected] www.vallourec.com

mailto:[email protected]

mailto:[email protected]

ENVIRONMENTAL PRODUCT DECLARATION - Vallourec · /DIN 18800/ to /DIN 18808/: ... 4 Environmental...

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