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Sustainable Aspects of Precast Concrete
Dean Frank, P.E., LEED Green Associate
Introduction
• Sustainable aspects of precast concrete
• Precast/Prestressed Concrete Institute (PCI)
best practices for:
• Quality
• Sustainable plant
operations
Link Between Quality and Sustainability
• Precast is an inherently sustainable material
• Improving quality and production processes can
make it better
Link Between Quality and Sustainability
Precast concrete is made:
• In a quality-controlled environment
• Uses materials efficiently
• Less construction waste
Link Between Quality and Sustainability
• Quality processes have a direct effect on the
degree to which precast concrete is considered
sustainable
• As quality improves, so do the sustainable
attributes
Link Between Quality and Sustainability
Durability:
• Higher quality
concrete = better
durability
• Durable concrete is
resilient to natural
and man-made
disasters
Link Between Quality and Sustainability
Durability:
• Better protection of reinforcement
• Prequalification of raw materials
• Optimization of concrete mix proportions
Link Between Quality and Sustainability
Reduced number of defective products
• Primary goal of QA program is to reduce
defects and rejected product
Link Between Quality and Sustainability
Reduced waste
• Due to control of raw materials
• Waste is more likely to be recycled
• Process water may be treated and reused
• Forms are reused
Link Between Quality and Sustainability
Optimum use of raw materials
• Precise batch quantities are possible
because of tight product tolerances
• Smaller members, longer spans, and less
material used on site = $ and environmental
savings
Plant Quality Operations
• Quality assurance and certification programs
played an important role in success of precast
concrete industry
• With more emphasis on sustainability, these will
become even more important
Plant Quality Operations
Quality control personnel be more involved with
tracking and coordinating processes that affect
the sustainability
• Raw material prequalification and tracking
• Accelerated curing with added heat or steam
Plant Operations
• Industry stakeholders demand improvement
• Can not improve something that is not
measured
• Precasters can also save money
Life Cycle Assessment
• What is an Life Cycle
Assessment (LCA)?
• Why LCA?
• Precast Concrete
Building LCA
• LCA Results
• Conclusions
What is LCA?
• Environmental accounting of environmental
impact
• Full assessment, rather than single criterion.
• Scientific, not subjective
What is LCA?
• Includes environmental effects due to:
• Extraction and fuel
• Manufacture of components
• Transportation
• Assembly and construction
• Operation
• Demolition, disposal, recycling, and reuse
http://www.bre.co.uk/greenguide/page.jsp?id=2106
What is LCA?
• Impacts quantified:
• Global warming potential
• Acidification potential
• Potential respiratory effects
• Eutrophication potential
• Photochemical smog creation potential
• Ozone depletion potential
What is LCA?
• Additional Inventory Items Tracked:
• Total primary energy
• Solid waste
• Water use
• Abiotic resource depletion
Why LCA?
• Increase transparency /
improve operations
• Benchmark precast
concrete industry’s
environmental performance
• Provide data for future
Environmental Product
Declarations (EPDs)
Precast Concrete Building LCA
Precast/Prestressed
Concrete Institute (PCI),
the Canadian
Precast/Prestressed
Concrete Institute (CPCI)
and the National Precast
Concrete Associate
(NPCA) partnered to
coordinate this research
Functional Unit
• Five-story commercial
office building
• Meets minimum
building energy code
requirements for R-
value
• Conditioned office
space for
approximately 130
people
Actual Building
Building Model
Building Form
• Plan dimensions
27 by 36 m (90 by 120
ft)
• Column grid spacing
9 by 12 m (30 by 40 ft)
• Total floor area
5000 m2 (54,000 ft2)
Elevation
Floor plan
LCA Study “Scenarios”
• 5 variations of building envelope
• 3 variations of structural framing
• 4 locations (Miami, Phoenix, Memphis, Denver)
Total of 60 buildings
Envelope and abbreviation
Structure and abbreviation
Steel (S)
Cast in place
concrete (C)
Precast
concrete (P)
Curtain wall (CW) CW-S CW-C CW-P
Brick and steel stud (S) S-S S-C S-P
Precast concrete (P) P-S P-C P-P
Insulated precast concrete (Pi) Pi-S Pi-C Pi-P
Insulated precast concrete and
thin-brick veneer (Pib)
Pib-S Pib-C Pib-P
“Baseline”
Comparative LCA
• Because this LCA study includes a comparative
assertion disclosed to the public, an independent
external panel of LCA and technical experts has
critically reviewed the methodology and results as
required by ISO 14044:2006.
• The research was conducted by a team comprised of
Morrison Hershfield, the Athena Institute, and Venta,
Glaser & Associates.
• Most comprehensive LCA study undertaken
Comparative LCA
• Data for all products was treated equally
• All buildings were compared using the same
functional unit and equivalent methodological
considerations:
• system boundary
• data quality
• allocation procedures
• decision rules on
evaluating inputs and
outputs
• impact assessment
Comparative LCA
In comparative assertions similar data quality:
• Time-related coverage
• Geographical coverage
• Technology coverage
• Precision
• Completeness
• Representativeness
• Consistency
• Reproducibility
• Sources of the data
• Uncertainty of the information
LCA Results
Good Data:
• Manufacturer data (9
precasters)
• PCA reports with LCI
data on cement and
concrete
• U.S. LCI database
(NREL)
LCA Results – Global Warming Potential
LCA Results – Global Warming Potential
LCA Results – Global Warming Potential
LCA Results – Global Warming Potential
LCA Results – Total Primary Energy
LCA Results – Total Primary Energy
LCA Results – Total Primary Energy
LCA Results – Total Primary Energy
LCA Results
Similar results for:
• Acidification Potential
• Potential Respiratory Effects
• Eutrophication Potential
• Photochemical Smog Creation Potential
• Solid Waste
All within 0 to 2% COV
LCA Results – Water Use
0
5
10
15
20
25
30
35
40
45
CW-S
CW-C
CW-P
S-S
S-C
S-P
P-S
P-C
P-P
Pi-S
Pi-C
Pi-P
Pib-S
Pib-C
Pib-P
Wateruse,cubicmeters
Denver, 73 years
0
5
10
15
20
25
30
35
40
45
CW-S
CW-C
CW-P
S-S
S-C
S-P
P-S
P-C
P-P
Pi-S
Pi-C
Pi-P
Pib-S
Pib-C
Pib-P
Wateruse,cubicmeters
Memphis, 73 years
0
5
10
15
20
25
30
35
40
45
CW-S
CW-C
CW-P
S-S
S-C
S-P
P-S
P-C
P-P
Pi-S
Pi-C
Pi-P
Pib-S
Pib-C
Pib-P
Wateruse,cubicmeters
Miami, 73 years
0
5
10
15
20
25
30
35
40
45
CW-S
CW-C
CW-P
S-S
S-C
S-P
P-S
P-C
P-P
Pi-S
Pi-C
Pi-P
Pib-S
Pib-C
Pib-P
Wateruse,cubicmeters
Phoenix, 73 years
LCA Results
Similar results for:
• Abiotic Resource Depletion (COV = 36%)
• Ozone Depletion Potential (COV = 0 to 15%)
http://guardianlv.com/2014/03/ozone-depletion-due-to-gases-banned-27-years-ago/
http://www.businessgreen.com/bg/analysis/2280429/ccc-shrinking-water-sources-put-uk-food-
production-at-risk/
LCA Conclusions
• Occupancy stage (operating energy) is
responsible for up to 96 to 98% of the
environmental impacts in a given impact
category regardless of climate
• Confirmed there is relatively little difference
between the various structural systems
LCA Conclusions
• Contrary to claims often made by other
building materials
• Concrete likely has the most potential to make
improvements
NAPCSPP Sustainable Plant Program
North American Precast Concrete Sustainable
Plant Program (NAPCSPP)
• Launched in 2015
• CPCI
• NPCA
• PCI
NAPCSPP Sustainable Plant Program
• Environmental Performance Standards
• Dust Control
• Process Water, Storm Water and Chemical
Management
• Noise Control
• Sustainability Performance Standards
• Energy
• Materials
• Transportation
• CO2 equivalent
• Total Primary Energy
• Water Consumption
Product Category Rule Development
Progress..
• LCA Complete
• Next Step = Develop PCR
• Same Industry Partners (CPCI, NPCA, PCI)
• ASTM International
• PCR Published on ASTM Website
Environmental Product Declarations
Progress..
• PCR Complete
• Gather Data with NAPCSPP
• Next Step = Develop EPDs
• Architectural and Insulated Wall Panels,
• Structural Precast Concrete Products and
• Underground Precast Concrete Products
Strategies for Environmental
Improvements
Energy Conservation:
• Alternate lighting, reducing fixtures,
increasing natural daylighting, etc.
• Optimize power factors motors
• Investigate onsite renewable energy
Strategies for Environmental
Improvements
Energy Conservation:
• Modify personnel behaviors and use of
natural ventilation
• Building envelope in good condition
• Improvements to HVAC
Strategies for Environmental
Improvements
Effective waste management:
• Waste audit
• Reduce or eliminate waste products
Strategies for Environmental
Improvements
Effective waste management:
• Reuse or repurpose waste product
• Pour leftover or waste concrete into
reusable forms
www.concreteconstructionweely.com
Strategies for Environmental
Improvements
Maximizing materials recycling:
• Divert as much recyclable material as
possible
• Reduce the amount of waste packaging
Strategies for Environmental
Improvements
Water management:
• Harvest rain water
• Use closed-loop systems for precast
operations
Strategies for Environmental
Improvements
Water management:
• Water conservation program
• Install water meters - quantify how much
water is being used and where.
Strategies for Environmental
Improvements
Water management:
• Install low-flow water fixtures
• Ensure irrigation systems do not over-water
or water non-vegetative surfaces
http://deervalleyplumbingsurprise.com/
Strategies for Environmental
Improvements
Mix design and optimization:
• Review concrete strength needs and revise
mix designs
• Increase the use of supplemental
cementitious materials
Strategies for Environmental
Improvements
• There are many other strategies to consider
• These metrics should be tracked over time
Precast Concrete is Well-Positioned
Concrete and precast concrete has great
potential to improve
• PCI Life Cycle Assessment Project
• As plants improve, so will sustainability
• Reduction in usage of portland cement
Conclusion
• Precast concrete is comparable to structural
steel…currently
• Both quality and sustainable plant practices
contribute to energy and materials savings and
reduction of environmental impacts
Conclusion
• It is best to track performance to improve
transparency and make improvements
• Although precast concrete is inherently
sustainable material, better quality assurance,
plant operation improvements, reduced
Portland cement usage will lead to better
environmental performance
"Sostenibilidad del Hormigón Prefabricado"

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"Sostenibilidad del Hormigón Prefabricado"

  • 1. Sustainable Aspects of Precast Concrete Dean Frank, P.E., LEED Green Associate
  • 2. Introduction • Sustainable aspects of precast concrete • Precast/Prestressed Concrete Institute (PCI) best practices for: • Quality • Sustainable plant operations
  • 3. Link Between Quality and Sustainability • Precast is an inherently sustainable material • Improving quality and production processes can make it better
  • 4. Link Between Quality and Sustainability Precast concrete is made: • In a quality-controlled environment • Uses materials efficiently • Less construction waste
  • 5. Link Between Quality and Sustainability • Quality processes have a direct effect on the degree to which precast concrete is considered sustainable • As quality improves, so do the sustainable attributes
  • 6. Link Between Quality and Sustainability Durability: • Higher quality concrete = better durability • Durable concrete is resilient to natural and man-made disasters
  • 7. Link Between Quality and Sustainability Durability: • Better protection of reinforcement • Prequalification of raw materials • Optimization of concrete mix proportions
  • 8. Link Between Quality and Sustainability Reduced number of defective products • Primary goal of QA program is to reduce defects and rejected product
  • 9. Link Between Quality and Sustainability Reduced waste • Due to control of raw materials • Waste is more likely to be recycled • Process water may be treated and reused • Forms are reused
  • 10. Link Between Quality and Sustainability Optimum use of raw materials • Precise batch quantities are possible because of tight product tolerances • Smaller members, longer spans, and less material used on site = $ and environmental savings
  • 11. Plant Quality Operations • Quality assurance and certification programs played an important role in success of precast concrete industry • With more emphasis on sustainability, these will become even more important
  • 12. Plant Quality Operations Quality control personnel be more involved with tracking and coordinating processes that affect the sustainability • Raw material prequalification and tracking • Accelerated curing with added heat or steam
  • 13. Plant Operations • Industry stakeholders demand improvement • Can not improve something that is not measured • Precasters can also save money
  • 14. Life Cycle Assessment • What is an Life Cycle Assessment (LCA)? • Why LCA? • Precast Concrete Building LCA • LCA Results • Conclusions
  • 15. What is LCA? • Environmental accounting of environmental impact • Full assessment, rather than single criterion. • Scientific, not subjective
  • 16. What is LCA? • Includes environmental effects due to: • Extraction and fuel • Manufacture of components • Transportation • Assembly and construction • Operation • Demolition, disposal, recycling, and reuse http://www.bre.co.uk/greenguide/page.jsp?id=2106
  • 17. What is LCA? • Impacts quantified: • Global warming potential • Acidification potential • Potential respiratory effects • Eutrophication potential • Photochemical smog creation potential • Ozone depletion potential
  • 18. What is LCA? • Additional Inventory Items Tracked: • Total primary energy • Solid waste • Water use • Abiotic resource depletion
  • 19. Why LCA? • Increase transparency / improve operations • Benchmark precast concrete industry’s environmental performance • Provide data for future Environmental Product Declarations (EPDs)
  • 20. Precast Concrete Building LCA Precast/Prestressed Concrete Institute (PCI), the Canadian Precast/Prestressed Concrete Institute (CPCI) and the National Precast Concrete Associate (NPCA) partnered to coordinate this research
  • 21. Functional Unit • Five-story commercial office building • Meets minimum building energy code requirements for R- value • Conditioned office space for approximately 130 people Actual Building Building Model
  • 22. Building Form • Plan dimensions 27 by 36 m (90 by 120 ft) • Column grid spacing 9 by 12 m (30 by 40 ft) • Total floor area 5000 m2 (54,000 ft2) Elevation Floor plan
  • 23. LCA Study “Scenarios” • 5 variations of building envelope • 3 variations of structural framing • 4 locations (Miami, Phoenix, Memphis, Denver) Total of 60 buildings Envelope and abbreviation Structure and abbreviation Steel (S) Cast in place concrete (C) Precast concrete (P) Curtain wall (CW) CW-S CW-C CW-P Brick and steel stud (S) S-S S-C S-P Precast concrete (P) P-S P-C P-P Insulated precast concrete (Pi) Pi-S Pi-C Pi-P Insulated precast concrete and thin-brick veneer (Pib) Pib-S Pib-C Pib-P “Baseline”
  • 24. Comparative LCA • Because this LCA study includes a comparative assertion disclosed to the public, an independent external panel of LCA and technical experts has critically reviewed the methodology and results as required by ISO 14044:2006. • The research was conducted by a team comprised of Morrison Hershfield, the Athena Institute, and Venta, Glaser & Associates. • Most comprehensive LCA study undertaken
  • 25. Comparative LCA • Data for all products was treated equally • All buildings were compared using the same functional unit and equivalent methodological considerations: • system boundary • data quality • allocation procedures • decision rules on evaluating inputs and outputs • impact assessment
  • 26. Comparative LCA In comparative assertions similar data quality: • Time-related coverage • Geographical coverage • Technology coverage • Precision • Completeness • Representativeness • Consistency • Reproducibility • Sources of the data • Uncertainty of the information
  • 27. LCA Results Good Data: • Manufacturer data (9 precasters) • PCA reports with LCI data on cement and concrete • U.S. LCI database (NREL)
  • 28. LCA Results – Global Warming Potential
  • 29. LCA Results – Global Warming Potential
  • 30. LCA Results – Global Warming Potential
  • 31. LCA Results – Global Warming Potential
  • 32. LCA Results – Total Primary Energy
  • 33. LCA Results – Total Primary Energy
  • 34. LCA Results – Total Primary Energy
  • 35. LCA Results – Total Primary Energy
  • 36. LCA Results Similar results for: • Acidification Potential • Potential Respiratory Effects • Eutrophication Potential • Photochemical Smog Creation Potential • Solid Waste All within 0 to 2% COV
  • 37. LCA Results – Water Use 0 5 10 15 20 25 30 35 40 45 CW-S CW-C CW-P S-S S-C S-P P-S P-C P-P Pi-S Pi-C Pi-P Pib-S Pib-C Pib-P Wateruse,cubicmeters Denver, 73 years 0 5 10 15 20 25 30 35 40 45 CW-S CW-C CW-P S-S S-C S-P P-S P-C P-P Pi-S Pi-C Pi-P Pib-S Pib-C Pib-P Wateruse,cubicmeters Memphis, 73 years 0 5 10 15 20 25 30 35 40 45 CW-S CW-C CW-P S-S S-C S-P P-S P-C P-P Pi-S Pi-C Pi-P Pib-S Pib-C Pib-P Wateruse,cubicmeters Miami, 73 years 0 5 10 15 20 25 30 35 40 45 CW-S CW-C CW-P S-S S-C S-P P-S P-C P-P Pi-S Pi-C Pi-P Pib-S Pib-C Pib-P Wateruse,cubicmeters Phoenix, 73 years
  • 38. LCA Results Similar results for: • Abiotic Resource Depletion (COV = 36%) • Ozone Depletion Potential (COV = 0 to 15%) http://guardianlv.com/2014/03/ozone-depletion-due-to-gases-banned-27-years-ago/ http://www.businessgreen.com/bg/analysis/2280429/ccc-shrinking-water-sources-put-uk-food- production-at-risk/
  • 39. LCA Conclusions • Occupancy stage (operating energy) is responsible for up to 96 to 98% of the environmental impacts in a given impact category regardless of climate • Confirmed there is relatively little difference between the various structural systems
  • 40. LCA Conclusions • Contrary to claims often made by other building materials • Concrete likely has the most potential to make improvements
  • 41. NAPCSPP Sustainable Plant Program North American Precast Concrete Sustainable Plant Program (NAPCSPP) • Launched in 2015 • CPCI • NPCA • PCI
  • 42. NAPCSPP Sustainable Plant Program • Environmental Performance Standards • Dust Control • Process Water, Storm Water and Chemical Management • Noise Control • Sustainability Performance Standards • Energy • Materials • Transportation • CO2 equivalent • Total Primary Energy • Water Consumption
  • 43. Product Category Rule Development Progress.. • LCA Complete • Next Step = Develop PCR • Same Industry Partners (CPCI, NPCA, PCI) • ASTM International • PCR Published on ASTM Website
  • 44. Environmental Product Declarations Progress.. • PCR Complete • Gather Data with NAPCSPP • Next Step = Develop EPDs • Architectural and Insulated Wall Panels, • Structural Precast Concrete Products and • Underground Precast Concrete Products
  • 45. Strategies for Environmental Improvements Energy Conservation: • Alternate lighting, reducing fixtures, increasing natural daylighting, etc. • Optimize power factors motors • Investigate onsite renewable energy
  • 46. Strategies for Environmental Improvements Energy Conservation: • Modify personnel behaviors and use of natural ventilation • Building envelope in good condition • Improvements to HVAC
  • 47. Strategies for Environmental Improvements Effective waste management: • Waste audit • Reduce or eliminate waste products
  • 48. Strategies for Environmental Improvements Effective waste management: • Reuse or repurpose waste product • Pour leftover or waste concrete into reusable forms www.concreteconstructionweely.com
  • 49. Strategies for Environmental Improvements Maximizing materials recycling: • Divert as much recyclable material as possible • Reduce the amount of waste packaging
  • 50. Strategies for Environmental Improvements Water management: • Harvest rain water • Use closed-loop systems for precast operations
  • 51. Strategies for Environmental Improvements Water management: • Water conservation program • Install water meters - quantify how much water is being used and where.
  • 52. Strategies for Environmental Improvements Water management: • Install low-flow water fixtures • Ensure irrigation systems do not over-water or water non-vegetative surfaces http://deervalleyplumbingsurprise.com/
  • 53. Strategies for Environmental Improvements Mix design and optimization: • Review concrete strength needs and revise mix designs • Increase the use of supplemental cementitious materials
  • 54. Strategies for Environmental Improvements • There are many other strategies to consider • These metrics should be tracked over time
  • 55. Precast Concrete is Well-Positioned Concrete and precast concrete has great potential to improve • PCI Life Cycle Assessment Project • As plants improve, so will sustainability • Reduction in usage of portland cement
  • 56. Conclusion • Precast concrete is comparable to structural steel…currently • Both quality and sustainable plant practices contribute to energy and materials savings and reduction of environmental impacts
  • 57. Conclusion • It is best to track performance to improve transparency and make improvements • Although precast concrete is inherently sustainable material, better quality assurance, plant operation improvements, reduced Portland cement usage will lead to better environmental performance