ENVIRONMENTAL PRODUCT DECLARATION

ENVIRONMENTAL PRODUCT DECLARATION OF PANEL IN RIGID POLYURETHANE FOAM 80 MM THICK STIFERITE GT

CPC CODE: 3695 - BUILDERS' WARE OF PLASTICS N.E.C REVISION 0 OF 23.06.2010 APPROVED ON 23.06.2010 PRE CERTIFICATION N. S-EP-00184.

PRESENTATION OF THE COMPANY AND THE PRODUCT THE COMPANY STIFERITE s.r.l., with its headquarters in Padua, viale Navigazione Interna 54, has worked in the heat insulation sector since 1963, the year in which the first machine in Europe for the continuous lamination of polyurethane foam was installed in Pomezia (Rome). The product was called Stiferite, using the root of the name of the company that was operating in Rome, Stifer, and the suffix ite, which refers to Isolanti TErmici (Heat Insulation). In 1968 the production was moved to the current headquarters in Padua and furnished with continuous automatic machinery that has reached todays annual production capacity of about 9 million square meters of heat-insulation polyurethane foam panels for the building industry.
The success of this product is also demonstrated by the fact that the Stiferite name has become synonymous with polyurethane foam panels thanks to a constant collaboration with designers, customers and users who have followed our work with enthusiasm, trust and constructive criticism.

Some of the recent successes to highlight: In 2000 the launch of a new lamination line that is able to produce the new Stiferite panels in Polyiso foam with D = 0,028 W/mK. In 2001 received the certification ISO 9001:2000 for the development and production of insulation panels. In 2005 the development of a new environmental mission focusing on analysing and reducing the impact of the productive operations and sharing environmental information with the public about the product, also based on the application of the LCA methodology. In 2007 STIFERITE develops a new line of panels with waterproof coatings characterized by a value of heat conductivity at D = 0,024 W/mK. In July 2007 STIFERITE certified and registered the first Environmental Product Declaration (EPD) for rigid polyurethane foam panels, referring to the Class S 60 mm thick STIFERITE panel, with the Swedish Environmental Management Council In 2008 the newly adopted formulations for the Polyisio foam allows for the panels to be 80 mm thick or more, with the heat conductivity at D = 0,026 W/mK. In 2009 the study of the life cycle analysis of STIFERITE Class B 40 mm thick panels was published. It was most widespread in the sector of insulation and waterproofing of coatings. An analysis by LCA of the STIFERITE GT panels follows in this document.

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THE GT PANEL AND PRODUCT COMPOSITION The STIFERITE GT panel is composed of Polyiso foam which is expanded by pentane and covered on both sides by the special multi-layer coating Duotwin. In the line of STIFERITE products, GT is the only panel that achieves excellent insulating performance (D = 0,024 W/mk) without metal coverings. This is thanks to the Doutwin covering which is impermeable to the gas contained within the cells and permeable for vapour. STIFERITE GT is a heat insulating product used both for building and in industry. It is distributed through traditional methods: direct sales wholesale of building materials waterproofing and coverings companies building companies prefabrication industry transformation industry Main applications: Stiferite GT is mostly used for heat insulation of walls, floors and coverings. Main features: Beyond great insulation performance (D = 0,024 W/mK), Stiferite GT also guarantees excellent dimensional stability, mechanical resistance, the ability to tolerate sustained temperatures up to 90-110 C and demonstrates good fire resistance. Product composition: The panel is made of polyurethane foam (88%W of which 6%W is pentane) and the multi-layer coating Duotwin (12%w). The density of the Polyiso foam is 30 kg/m3. Duration: The polyurethane foams are the result of a stable and non-reversible chemical reaction that guarantees consistency and lasting duration of its main characteristics and features. There is no evidence of physical or chemical decay when the product is used normally. The actual duration of the insulation panel can therefore be assumed to be equivalent to the life of the building or manufactured product where it is located.

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PRODUCT PERFORMANCE In order to better contextualize the information presented, related to the heat performance of the panels, Table 1 reports some characteristics. The published data reported in this EPD are only applicable to the 80 mm thickness (highlighted).
Table 1-Extract of the technical records for the GT panels

Parameter Initial Heat Conductivity Reported Heat Conductivity

Symbol

UdM mm W/mK 20 30 40

Thickness of the panel STIFERITE GT 50 60 70 0,022 80 90 100 110 12

90/90,l

W/mK

0,024

Reported Heat Resistance

RD

m K/W

0.83 1.25

1.67

2.08

2.50

2,92

3.33

3,75

4.17

4,58

5.00

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REPORT OF ENVIRONMENTAL PERFORMANCE This section illustrates the main characteristics and results of evaluation of the environmental aspects that were carried out from the viewpoint of the life cycle, according to the LCA methodology. METHODOLOGY The quantification of the environmental performance was carried out as set out by the EPD General Program Instruction, according to the LCA (Life Cycle Assessment) and regulated by the international standard ISO Series 14040. Since a specific PCR reference is missing, the study also considers the document PCR Plastic Foam1. The data refer to the production of 80 mm STIFERITE GT panels in 2008 and were gathered at STIFERITE. The study also used the Boustead Model database for the general data selected. There is less than a 5% contribution from the other general data in the final results. Regarding the unit that the results apply to (working unit) to describe the panels' production, the production of 1 m2 of panel was chosen. In order to make the total results as understandable as possible, the results for the unit of heat resistance (R = 1m 2K/W), mass (1 kg) and volume2 (1 m3) are also being presented here. LIMITS OF THE SYSTEM AND MAIN HYPOTHESES The analysis considered the entire productive system as illustrated in Figure 1, considering the single operations which start with the production of the raw materials, then covers the production and transportation of energy carriers and the final product, as well as the intermediary transportation involved. In the following diagram, the phases discussed using data coming from the company or from direct suppliers (blue areas) can be distinguished from the data taken from reference databases (white areas). Also distinguishable is the subdivision in the three main phases (Upstream, Core and Downstream). The limits of the system do not consider the usage phase of the product and the recovery treatments of energy and materials for which production discards are designated. As for the employment of the materials, the specific technical data of the product is referred to, while the data related to the production process are allocated based on the total production. In particular, the auxiliary activities including heating, lighting, consumption of materials, air emissions are also included in the parameters of the system.

1 2

Factory made insulating material made of foam plastics, Institut Baum und Unwelt e.V. Rev 30/01/2009. The reference to the volume is made based on the average density of the panel equal to 33,8 kg/m3.

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UPSTREAM PROCESS
POLYOILS PRODUCTION ISOCYANIDE (MDI) PRODUCTION TRANSPORT

CORE PROCESS
DISTRIBUTION ENERGY CARRIERS PRODUCTION

SEMI-MANUFACTURED SP1873

ADDITIVES PRODUCTION

S Y S T E M B O U N D A R I E S

POLYMERIZATION AND EXPANSION COMBINATION AND TRIMMING

PROCESS EMISSIONS

COATING PRODUCTION

TRANSPORT

PROCESS EMISSIONS PRODUCTION TRIMMINGS

PACKAGING

PACKAGING PRODUCTION

DOWNSTREAM PROCESS
DISTRIBUTION

LANDFILL

USE PHASE
Figure 1 General flow chart of the production process for GT panels. The production system at STIFERITE is identified with the Core Process. The dotted cells are qualitative

In the case of transport, the study examined the one necessary for the semi-manufactured products and used materials as well as the phases of internal movement and delivery. The distribution refers to the distance to the regional capitals in Italy. The data can also be considered for delivery to other areas. In regard to the referenced energy mix, the data used for the main raw materials refer to the average European mix, except for the production of coatings characterized by the French mix, while data relating to the Italian energy mix were used for the production process. The impacts due to scrap incineration are evaluated. It can be hypothesized that the manufactured product, at the end of its life, will end up in a refuse tip. The possibility of the complete release of pentane into the atmosphere is considered in a precautionary way. However this is normally prevented unless the material is broken, crumbled or smashed.

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ENVIRONMENTAL PERFORMANCE According to the rules of the EPD System, the following environmental performance refers to the 80 mm thick STIFERITE GT panels with details about the natural resources used (Tables 2 and 3) and release of substances into the environment (Table 4) as well as waste production (Table 5).
Table 2 Resources with energy contents ( reported values no less than 1MJ)

Category

Resources with energy contents

Upstream

Core Process

Downstream

STIFERITE GT 80 mm TOTAL

Related results Panel total MJ/m3 MJ/m2K/W

MJ/m2 2 8

MJ/m2 0 0

MJ/m2 0 0

MJ/m2 2 8

MJ/kg

Hydroelectric

25 100

1 2

1 3

Renewable sources

Wood and biomass Other renewable sou Total renewable sou Coal

13

10

11
22 96 118 14 250

138
275 1200 1488 175 3125

3
7 29 36 4 75

4
8 36 44 5 92

Non-renewable sources

21 87 111 13 232 242 -

1 8 7 1 17 18 1

0 1 0 0 1 2 -

Oil Gas Other non renewable sou Total non renewable sou GER3

261 1

3263 13

78 0

96 0

Whereof electricity (Stiferite)

GER: Gross Energy Requirement

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Table 3 - Resources without energy contents (reported values no less than 1g)

Resources without energy contents

Category

Upstream

Core Process g/m2

Downstream

STIFERITE GT 80 mm TOTAL g/m2 g/m3

Related results Panel total g/m2K/ W g/kg

g/m2

g/m2

Total renewable sources

Sodium chloride

Renew able source s.

2422
427

27

2422

30275

727

896

Non -renewable sources

Calcium carbonate Oxygen Potassium chloride Other nonrenewable

463

139

171

402 72 144 3437 3437 885

10 19 19 3

31 58 58 0

402 72 155 3514 3514 888

4 0

121 22

149 27

46

46

57

sources Total nonrenewable sour TOTAL WATER [kg/UF]

30325 30325 11100

1055 1055 266

1300 1300 328

Table 4 -Potential contribution to the main environmental effects from the production process of the 80 mm thick GT panel

Indicators

Unit of measurement kg CO2 eq. g SO2 eq. g PO43- eq. g C2H4 eq. g CFC11 eq.

Up 1 m2

STIFERITE Core Down GT 80 mm TOTAL 1 m2 1,3 7 1 1 0 1 m2 0,1 1 0 61 0 1 m2 11,2 56 8 64 0

Related results Panel total 1 m3 140,2 706 93 798 0

1 m2K/W

1 kg 4,1 21 3 24 0

GWP100 AP EP POCP ODP 8 di 12

9,8 48 7 2 0

3,3 17 2 19 0

The emissions into the air and water are presented as aggregated in Table 4, providing the indicators from the EPD International System Another important piece of information relating to the description of the environmental impact of the system is the link to waste production. In this sense, Table 5 shows the total waste generated from the production activity of 80 mm STIFERITE GT panels.

Table 5 - Total waste production by the system. Data in g

Type of waste [g] Non dangerous Dangerous Total

Up 1 m2 1321 44 1365

STIFERITE Core Down GT 80 mm TOTAL 1 m2 133 3 136 1 m2 2711 0 2711 1 m2 4165 47 4212

Related results Panel total 1 m3 52063 588 52651

1 m2K/W

1 kg 1541 17 1558

1250 14 1264

USAGE PHASE For this phase, it is possible to consider the following: The performance of the material, presented in Table 1, refers to its main function and is essentially traced back to its heat resistance. The 80 mm thick STIFERITE GT panels are inert, undissolvable and non-metabolizable. Therefore their characteristics remain unchanged over time and their duration coincides with the structure where they are installed. The physical chemical characteristics of the pentane in the panel makes the gas permanently entrapped inside the panel until its disposal (UNI EN 13165).

ADDED INFORMATION AND REFERENCES In this section of the declaration, further information linked to the management of the company and the procedure for the validation of the document follows.

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THE COMPANY'S ENVIRONMEN TAL MISSION STIFERITE S.r.l. has a management system which is certified according to the voluntary Quality Standards UNI EN ISO 9001. Wanting to make the environmental performance of its products accessible to the public, STIFERITE has published this environmental declaration about the product according to the EPD standard. STIFERITE points to the following as some of the actions taken to improve its own environmental performance: the reduction of gas expenditure for heating thanks to an improved level of insulation of the manufactured products, illustrated by the LCA studies conducted over recent years; sending scrap to the thermal-exploitation systems with the recovery of energy happening outside of the company's system. For this reason, it is not counted within the parameters of the present EPD. A heat efficiency improvement of its products and the issue of products to the market that conduct less heat so that they increase the insulation level of the manufactured products and consequently lower the energy expenditure.

CONTACTS For more information about STIFERITE or this environmental declaration, you can contact Fabio Raggiotto +39 049 8997917, e-mail fraggiotto@stiferite.com. Otherwise, please consult the website, www.stiferite.it. Technical support was given to STIFERITE by Studio Life Cycle Engineering in Turin (www.studiolce.it info@studiolce.it).

INFORMATION ABOUT TH E CERTIFICATION AUTHORITY AND PCR This EPD refers to the International System EPD developed by the International EPD Consortium (IEC) and is available, along with the current standards, on the website, www.environdec.com

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PCR not available. EPD undergoing pre-certification Independent verification of the declaration and data, according to ISO 14025: Internal Third party verifier: RINA Services S.p.A. (www.rina.org) (accredited to SWEDAC n 1.812) for the pre-certification Via Corsica 12, I-16128 Genova (Italy) Tel: +39 010 53851 Fax: +39 010 5351000 www.rina.org Valid until: 23.06.2011 EPD belonging to the same product category, but coming from different programmes, can be unsuitable for comparison. x external

BIBLIOGRAPHY Life Cycle Assessment of the production cycle for panels in rigid polyurethane 80 mm STIFERITE GT, Final Report 1.0 8 February 2010.
Gascogne Laminates - Questionnaire relatif lecobilan de Duotwin M20 PP20 / KE120 / Glue / Met PET 12 m, 2008

draft PCR (Product Category Rules) basic module CPC 36 Rubber and plastic products version 5 dated 2009-08-10 General Programme Instruction for EPD, dated 29/02/2008 draft PCR dellInstitut Bauen und Umwelt E.V. (IBU) PCR Foam Plastic Rules for Environmental Product Declarations- Factory made Insulation Material from Polymer Foam version 2009-01-30 Intenational EPD Consortium, General Programme Instructions (EPD)ver.1, Supporting annex for an international EPD system dated 29/02/2008 Sources of data used from: Ecoinvent database, Boustead database, Italian database LCA, International Energy Agency, PlasticsEurope STIFERITE specifications (www.stiferite.com)

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GLOSSARY Acidification [AP]: phenomenon in which the atmospheric precipitation has a pH which is lower than average. It damages forests and farming, as well as aquatic systems and manufactured products. It is caused by the emission of SO2, NOx, and NH3, that are then included in the indicators of Acidification Potential (AP), expressed by the g SO2 produced. Heat Conductivity [ ]: It is the amount of heat transferred in a perpendicular direction to the surface of a unit area, due to a temperature difference, in a time unit. The movement exclusively comes from the difference in temperature. In easier terms, it is the ability of the substance to transmit heat. Heat conductivity presented as *D] represents the amount established for a life of 25 years by 90% of the production with 90% statistical reliability. Ozone Depletion Potential [ODP]: depletion of the ozone layer, having the property of blocking the ultraviolet sunlight component, due to especially reactive compounds that originate from Chlorofluorocarbons (CFCs) or Trichlorofluoromethane (CFM). The substance used as reference for the ODP (Ozone Depletion Potential) is Trichlorofluoromethane, or CFC-11. Greenhouse effect [GWP100]: Phenomenon in which the infra-red rays emitted from the earth's surface following solar heating are absorbed by molecules found in the atmosphere and re-emitted as heat, causing a global warming of the atmosphere. The indicator used is GWP100 (Global Warming Potential calculated for 100 years) that primarily includes the emissions of carbon dioxide, the main ingredient in the greenhouse effect, in addition to other gases which have lower infra-red absorption, such as methane (CH4), nitrous oxide (N2O), chlorofluorocarbons (CFCs), that are expressed based on their absorption of CO2 (g CO2 ). Eutrophication Potential [EP]: Nutrient enrichment of waterways that provokes imbalances in the aquatic ecosystem due to excessive development caused by the lack of nutritive limitations. Eutrophication Potential (EP) primarily includes phosphorous and nitrogen. It is expressed in equivalent grams of oxygen (g PO43-). Photochemical Ozone Creation Potential [POCP]: The production of compounds that are able to cause an oxidization reaction that produces ozone in the troposphere. The POCP (Photochemical Ozone Creation Potential) is mostly COV (Unstable Organic Compounds) and it is expressed in grams of ethylene (g C2H4). Heat resistance [R]: It measures the ability of something to transfer heat in a certain direction, by a given thickness and surface unit. It is inversely proportional to heat conductivity and directly proportional to the thickness. The declared heat Resistance [RD] represents the value established for a life of 25 years reported by 90% of the production with 90% statistical reliability.

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