Life Cycle Assessment of Composites April 2005 Paul Thistlethwaite Environment Division / Centre for Sustainable Construction

Presentation content BRE Methodology and the Green Guides Green Guide to Composites Project Aims and Objectives Funding and Structure (partners) How work was carried out Paper guide Web tool Open discussion and web tool examples

Green Guide to Specification Simple to use Element based Environmental impacts of building elements Based on LCA A,B,C rating

The Ecopoint and A, B and C ratings

IssuesMeasurementWeighting ECOPOINTSECOPOINTS Derivation of Ecopoints

Compass Project Introduction Composite materials more widely used in varied markets More emphasis on environmental aspects of manufacturing Sustainability –Environment –Society –Economy

Aims Build guides around simple scoring method for those new to sustainability –Paper and web based (free) To be used by SME companies Ensure guide is applicable to wide range of products, processes and methods Locate existing and new data for the guide Implications of different material and processing choices

Funding and Structure Composite Tooling and Structures Curv Composites DTI Engineered Composites Fibreforce Composites Hexcel Composites Klargester Environmental Lotus Engineering Menzolit UK DTI - Sustainable Technologies Initiative Principle partners –BRE –NetComposites Steering group members and contributors in kind Michael Stacey Architects Network Group for Composites in Construction (NGCC) Plastech Thermoset Techtronics Polymer Engineering Polynorm Reichhold Saint Gobain Vetrotex Taylor Woodrow Vestas Blades UK

How the work was carried out Data collection –Environmental –Social Models creation LCA Publishing

Data collection What Questionnaire (standard) – input materials, energy, transport, water consumption, emissions, general process activity. Social risk, remuneration How Piloted data capture first Data from partner organisations NetComposites as data collectors

Variables to be accommodated in model Component Process Materials –Matrix –Fibre –Pre-impregnated materials Sub-Process variations

Production Stages and LCA framework

Creating the models COMPONENT COMBINATIONS (+MASS RATIOS) PRE-MADEFIBRERESINPROCESS MODULES QUESTIONS ECOPOINTS RATING (A-E)

Components 1m 2 double curvature panel (example) –Constant bending stiffness –Base line 4mm thick - 20% fibre volume fraction –Alternative thickness calculated –Mass of fibre and matrix calculated and used in data Small complex panel –Constant volume –Volume base 770cm 3 1m wide x 8m long sandwich panel –Constant bending stiffness –4mm skins and 25mm thick core base

Processes Hand Lay-up Spray-up Vacuum Bag Moulding Resin Infusion Resin Transfer Moulding Autoclave Moulding Pultrusion Compression Moulding

Matrices, Fibres and Pre-impregnated Matricies Polyester LS Polyester Filler options Epoxy resin Polypropelene Fibres CSM Glass rovings Woven glass Hemp Carbon Pre-impregnated SMC GMT LFT PP/PP Twintex

1m 2 Double Curvature Panel

Example of a model

Hand Lay-up Base Case Polyester Resin (20% volume fraction) Chopped strand mat (Glass) (80% volume fraction) No filler Normal mould release Gelcoat brushed Manually cut fabric Closed mechanical resin mixing Resin applied by brush Consolidate with roller Cure at room temperature Trim by hand Post cure at room temperature Clean mould

Social impacts

Social data collection and assumptions Exposure to toxic chemicals eliminated with use of PPE Best case is to reduce need for PPE in workplace PPE only used when all other measures to limit exposure eliminated –Reduction of toxic substances –Reduce emissions –Minimise operator to exposure

Social data

Remuneration Salary details collected Social indicator Single geographical area Separated by process Graded A-E

Publication - paper based guide Guide divided into sections –Part 1. Introduction –Part 2. How the Green Guide was compiled –Part 3. Stages of composite production –Part 4. Composite processes –Part 5. Green Guide ratings for composites

Part 3 Stages of the Composite Production In all sections full descriptions given Charts giving an example of impact within a process Recommendations on sustainable improvement –Such as inclusion of filler to reduce the amount of resin present

Production Stages - All

Individual

Part 4 Composite Processes Listing of the eight processing methods to be studied Base case scenario chosen and studied Full description of the process and parameters Pie chart breakdown of the impacts –Gives an easy pictorial representation Analysis

Double Curvature Panel: Hand Lay-up Consider typical process Model as base case Adapt base case for individual options Calculate impact of options Evaluate significance of variations Focus on significant options only

Base case and other models

Hand Lay-up base case impacts

Pultrusion base case impacts

Part 5 Green Guide Ratings for Composite Products Green Guide ratings for Composite Products –A double curvature panel –A flat panel –A small complex moulded component Full assessment of the case models Summary ratings

Diagram example of composite table

Web based guide Interactive version of the guide Comparisons between the processes modelled by the partners Hosted on the NetComposites site and linked to BRE Allows more options than paper based guide