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Building Materials
Jan Bujnak
University of Zilina, Slovakia
Life Cycle Assessment (LCA) technique for assessing the environmental
aspect and potential impacts associated with product (building).
Most widely used method (MWU) - predominant method for steel or
concrete material to be manufactured, shipped and erected on a typical
construction site. Each construction project is unique; no two projects
are completed or conducted in the exact same way.
The following three environmental concerns are focused:
- Energy consumption,
- Harmful air emissions & their impacts on global warming,
- Depletion of limited natural resources.
Energy consumption
Increased energy prices,
Instability in major oil producing countries,
Energy shortage in the not so distant future,
Alternative energy sources,
Improved energy efficiency in existing systems
Air Emissions
Global warming & climate changes.
Building industry is the largest contributor to the total upstream dioxide
carbon CO2 emissions accounting for 7% of the annual global greenhouse
gas emissions.
Resource Depletion
The construction industry accounts for a vast majority of raw material
consumers.
Source :M atos and Wa gner, USGS, 1 99 8
Solutions:
- new concrete with recycling admixtures
- refinement of the steel manufacturing process with to nearly 100%
recycling content.
Regional Characteristics
Obviously the MWU method can be different in other geographical areas.
The true comparison between the use of concrete and steel as building
materials should assume a location and the relevant flows for the region.
Time Frame
The construction industry is very cyclical. The predominant or most
common method today may not be the same one tomorrow. Changes in
markets have effects on the MWU method.
Backwards Modeling
composite slab
composite column
composite beam
floor = beam + slab
Concrete Production
Concrete production involves the batching or mixing in standard ratio
the major inputs:
- Portland cement,
- fine aggregate,
- coarse aggregate,
- water & additional admixtures.
Generally, there are two types of batching system:
- wet-batch system or central mix system (the components are mixed
at the batch plant before loading on the mix truck),
- dry-batch system (the components are mixed in the truck en-route
to the job site).
Cement Production
Aggregate Production
Aggregate is divided into two categories:
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Formwork Production
Formwork is necessary component of cast-in-place concrete. Forms are
usually constructed of different types of plywood:
HDO high density overlay,
MDO medium density overlay,
Normal.
Plywood is manufactured by layering several layers of layers of woods
veneer with resin.
Obviously, formwork is rented to the contractor on the temporary per
job basis. Regional formwork distributors stock several standard size
forms directly from manufactures.
Reinforcing Bar
Typically, re-bars are available from local warehouses and distributors
that stock obvious size and lengths. There are produced in steel bar mills.
Concrete placement
On a multi-story project, concrete is placed using a bucket or pump
truck. The energy requirements include the operation of mix trucks and
equipment during the concrete pouring (vibrators and other tools) and
form removals, once the concrete sets.
The molted liquid is then casted, where it is converted from liquid to solid
by cooling.
The casted steel is thrn continues to the reheat furnace, where it is
decaled, scarfed, and hot-rolled into standard shapes.
The EAF process is very energy intensive, especially electrical.
Steel Fabrication
Steel fabrication involves cutting, drilling, and fitting of raw steel
members to meet the project specifications. The primary output from the
steel fabrication shop is a combined member, ready for erection at the
construction site.
First, the beams are cut to the required length by heavy duty band saws.
The ends are then drilled to provide bolted connections. In some cases, a
punch is used. A plasma cutter is used, if irregular angles are to be cut.
Fabrication shops have multiple stations for fitting and welding
processes. If painting is required, the structural parts undergo surface
preparation (sand blasting or hand sanding).
Fireproofing production
Concrete production
Concrete production is required for the floor slab system with only
minimal reinforcement.
LCA results
The results are:
- total raw emission of carbon dioxide in kg,
- total energy requirement in MJ,
- total amount of natural resources depleted in 100 kg.
Energy Consumption
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Over 50% of the total energy requirement for beam production is used in
the production of electricity. A breakdown is depicted in the figure:
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The concrete production accounts for half (51%) of the total energy
requirement of cast-in-place frame structure. Extracting transportation
requirements from product system, concrete production remains the
largest consumer of energy resources (40%). As is shown in the next
figure, the production of electricity has less impact on the concrete frame
building (28%), and its impact is primarily due to steel re-bar
production.
Air Emissions
The raw results indicate that concrete has a 25% greater impact on
CO2 emissions than steel both are of the same order of magnitude.
Carbon dioxide is released in almost all processes from chemical
reactions or through burning of fossil fuels for kiln heating or to provide
electricity to power production facilities.
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Resource Depletion
The nine of natural resources listed in the table are primary materials
used in individual unit processes for both steel and concrete frame
building constructions. The list includes renewable and non- renewable
types, while other auxiliary materials could be required for process flows.
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The conclusion is that a concrete construction uses four times the amount
of total raw materials than steel. Moreover, the use of scrap iron also
accounts for some difference, because recycled steel is not counted as one
of the raw resources.
The important result to note is that both materials, in the construction of
a single building require over 10 thousands tons of gross raw materials
(without water) and consume more than 100 thousands tons of water.
These impacts cannot be ignored.
Concluding remarks
While the question posed is which material is better, steel is clear
winner in CO2 emissions and resource depletion, with 25% less total
dioxide carbon emission and 68% less total natural resources used.
The energy consumption is equal and therefore does not effect the
determination.
But what if total energy requirement of steel exceeded concrete, for
instance due to requirements to receive steel from more energy
intensive foreign mills.
Where does it say that impacts of energy consumption are less
important than CO2 emissions and resource consumption?
Further, what is an acceptable threshold of CO2 emissions?
Thus, decision makers have to avoid identifying winners and take
into account that both materials have a significant impact on the
global environment.
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