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INSULATED METAL WALL & ROOF PANELS Environmental Product Declaration Metl-Span is part of NCI Group, Inc., the single largest producer of metal building components in North America. With its groundbreaking, UL-certified, ISO-compliant products, Metl-Span leads the industry in the development of energy-efficient and cost-effective panel systems. Since its inception, our company has been dedicated to a cleaner, safer environment. As evidence of our leadership in this role, we offer this Environmental Product Declaration, which provides a detailed analysis of our products’ environmental manufacturing footprint, based on an ISO-compliant Life Cycle Assessment (LCA). Metl-Span’s LCA measures the impact of its product on the environment during all phases of its life from supply chain, through the manufacturing process, to product use and end of life. ISO LCA standards are applied to accurately report the product’s impact on the environment. Find your earth-friendly products at: METLSPAN.COM METL-SPAN®

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Page 1: insulated metal wall & roof panels - Metl-Spanmetlspan.com/wp-content/uploads/2013/01/MetlSpan-EPD-Insulated... · INSULATED METAL WALL & ROOF PANELS Environmental Product Declaration

Environmental Product Declaration

Metl-Span® Insulated Metal Wall and Roof Panels CF42, CFR42, and CF30A According to ISO 14025

Environment

1

INSULATED METAL WALL & ROOF PANELS

Environmental Product Declaration

Metl-Span is part of NCI Group, Inc., the single largest producer of metal building components in North America. With its groundbreaking, UL-certified, ISO-compliant products, Metl-Span leads the industry in the development of energy-efficient and cost-effective panel systems.

Since its inception, our company has been dedicated to a cleaner, safer environment. As evidence of our leadership in this role, we offer this Environmental Product Declaration, which provides a detailed analysis of our products’ environmental manufacturing footprint, based on an ISO-compliant Life Cycle Assessment (LCA).

Metl-Span’s LCA measures the impact of its product on the environment during all phases of its life from supply chain, through the manufacturing process, to product use and end of life. ISO LCA standards are applied to accurately report the product’s impact on the environment.

Find your earth-friendly products at: METLSPAN.COM

METL-SPAN®

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Environmental Product Declaration

Metl-Span® Insulated Metal Wall and Roof Panels CF42, CFR42, and CF30A According to ISO 14025

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UL Environment CERTIFIED

This declaration is an environmental product declaration in accordance with ISO 14025 that describes the environmental characteristics of the aforementioned product. It promotes the development of sustainable products. This is a certified declaration and all relevant environmental information is disclosed.

PROGRAM OPERATOR UL Environment

DECLARATION HOLDER NCI Group, Inc.

DECLARATION NUMBER 11CA63892.101.1

DECLARED PRODUCT Metl-Span Insulated Metal Wall & Roof Panels

REFERENCE PCR UL Environment PCR for Insulated Metal Panels & Metal Composite Panels, and Metal Cladding: Roof and Wall Panels

The PCR review was conducted by:

UL Environment

PCR confirmed by Panel Review

333 Pfingsten RoadNorthbrook, IL 60611Tel: 847-274-9879Email: [email protected]

This declaration was independently verified in accordance with ISO 14025 and EN 15804 by Underwriters Laboratories □ INTERNAL □ EXTERNAL

Loretta Tam, UL Environment

This life cycle assessment was independently verified in accordance with ISO 14044 and the reference PCR by:

Francios Charron-Doucet, Quantis International

DATE OF ISSUE November 1, 2012

PERIOD OF VALIDITY 5 Years

CONTENTS OF THE DECLARATION

Product definition and information about building physics

Information about basic material and the material’s origin

Description of the product’s manufacture

Indication of product processing

Information about the in-use conditions

Life cycle assessment results

Testing results and verifications

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Environmental Product Declaration

Metl-Span® Insulated Metal Wall and Roof Panels CF42, CFR42, and CF30A According to ISO 14025

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Description of company / organization and product

Description Company

For over 45 years, Metl-Span® has been the acknowledged leader in insulated metal panels for a variety of building applications. And we continue to set new standards in technological advancement, design innovation, aesthetic appeal, manufacturing quality, and service excellence. Our seven strategically located, state of the art manufacturing facilities today produce a full range of insulated panels for the architectural, commercial/industrial, and cold storage industries, for new and retrofit construction. We offer panels designed specifically for use in walls, roofs and ceilings, in an ever-widening array of colors and finishes, fitments and performance specifications. Our mission is clearly defined: To deliver the highest-quality, most energy-efficient solutions to insulate and protect our world. That means producing panels which meet or exceed the U.S. Green Building Council’s criteria for sustainability, reusability, recyclability and other attributes, thereby enabling our customers to qualify for credits in the Leadership in Energy and Environmental Design (LEED) Rating System, leading to Silver, Gold or Platinum certifications.

Product Definition

Product Description

Metl-Span insulated metal panels (IMPs) consist of Class I polyurethane foam sandwiched between two sheets of cold rolled galvanized steel. Several configurations of IMPs exist depending on where and how they are used (e.g. building walls, roofs, cold storage, etc.) and the styling as desired by the architect.

Three IMP products are covered by this EPD:

> CF42: 3-inch thick × 42-inch wide insulated metal panels manufactured on a continuous line for wall insulation Profile names are Striated, Mesa, Light Mesa and Fluted.

> CFR42: 3-inch thick × 42-inch wide insulated metal panels manufactured on a continuous line for roof insulation

> CF30A: 3-inch thick × 30-inch wide architectural insulated metal panels manufactured on a discontinuous line for wall insulation

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Environmental Product Declaration

Metl-Span® Insulated Metal Wall and Roof Panels CF42, CFR42, and CF30A According to ISO 14025

Environment

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Metl-Span panels are comprised of an advance urethane core that is injected between two pre-finished steel panels, forming a single, all-in-one unit. The result is the most thermally efficient panel available. Finished panels are mounted to the building’s framework – outboard of the structural supports – providing continuous insulation with no thermal bridges for maximum thermal efficiency. Architectural wall panels also have a specially formed barrier side joint that permits the hidden application of vapor sealant within recessed grooves, creating an impenetrable water and vapor seal that is protected from the effects of extreme weather.

Furthermore, the exterior face sheet of all Metl-Span insulated wall panels are treated with a base primer followed by a premium coating of full-strength 70 percent PVDF fluoropolymer finish (or a siliconized polyester finish, where economy is a primary consideration). Naturally, Metl-Span panels meet or exceed code requirements for foam plastic insulation.

Applications

Thanks to their excellent insulating and weatherproofing characteristics, as well as their very competitive installed cost, Metl-Span panels are ideally suited to use in walls, ceilings and roofs for commercial, industrial and institutional buildings of virtually any scale, in both new and retrofit construction. Successful applications include manufacturing facilities, warehousing and distribution centers; schools, sports complexes, museums and convention centers; corporate offices, banks and municipal buildings; retailing locations, including auto dealerships; aircraft hangars and service facilities; cold-storage and food-processing plants. Significant examples include the architecturally unique campus buildings of Oakland Community College in Oakland, CA and the giant final assembly plant for the Boeing 787 Dreamliner in North Charleston, SC.

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Environmental Product Declaration

Metl-Span® Insulated Metal Wall and Roof Panels CF42, CFR42, and CF30A According to ISO 14025

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Product Specifications

Singular Effects

Quality Control

The quality of Metl-Span’s products reflects the company’s 45-year history as a pioneer in insulated metal panel development. We remain completely dedicated to bringing forth design innovation and technology improvements that shape industry standards.

Metl-Span has established programs and policies designed to promote and ensure company-wide dedication to product quality. Meeting our goal of world-class product quality and delivering on our promises to customers requires each employee to live the company’s values of integrity, teamwork, commitment and excellence, consistently, every day.

AS-TL1923AASTM A240ASTM A653ASTM A792ASTM A924ASTM C273ASTM C518ASTM C1363ASTM D523ASTM D1014ASTM D1621ASTM D1622ASTM D1623ASTM D1729

ASTM D2244ASTM D2794ASTM D3359ASTM D4145ASTM D7091ASTM E18ASTM E72ASTM E90-99ASTM E283ASTM E330ASTM E413ASTM E1592ASTM E1680ASTM E1886

ASTM F1642 FM 4471FM 4880FM 4881GSA-TS01-2003Florida Department of Business and Professional Regulation - RoofFlorida Department of Business and Professional Regulation - WallUL 580 ASCE 7ASTM A755 ASTM D968

Fire-related standardsASTM E84ASTM E119CAN/ULC S101CAN/ULC S102CAN/ULC S126CAN/ULC S134CAN/ULC S138

Fire-related standardsNFPA 259NFPA 285NFPA 286UL 263UL 723

Water-related standardsAAMA 501.1ASTM D2247ASTM E331ASTM E1646

Weathering-related standardsASTM B117ASTM D4214ASTM E1996

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Environmental Product Declaration

Metl-Span® Insulated Metal Wall and Roof Panels CF42, CFR42, and CF30A According to ISO 14025

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Delivered Product Configurations

Panels are customized according to building site. Variations in panel configuration are as follows:

CF42 Insulated Metal Wall Panels

Panel ThicknessCF Mesa: 2", 2-1/2", 3", 4", 5", 6"CF Light Mesa: 2", 2-1/2", 3", 4"CF Partition: 2", 2-1/2", 3", 4" (2-3/4" thickness also available from Nevada plant)

Panel Width CF Mesa & Light Mesa: 36", 42"CF Partition: 44-1/2"

Panel Length 8'-0" to 53'-0"Joint Configuration Offset double tongue and groove with extended metal shelf for positive face fastening

Panel Facings

Exterior Face: Stucco-embossed, G-90 galvanized and/or AZ-50 aluminum-zinc coated steel in 26 Ga., 24 Ga., and 22 Ga..Interior Face: Succo-embossed, G-90 galvanized, and/or AZ-50 aluminum-zinc coated steel in 26 Ga., 24 Ga., and 22 Ga.

Orientation Horizontal or VerticalCFR42 Insulated Metal Roof PanelsPanel Thickness 2", 2-1/2", 3", 4", 5", 6"Panel Width 30", 36", 42"Panel Length 9'-6" to 53'-0"

Joint Configuration Mechanically closed single lock standing seam at the exterior side joint. The interior side joint is a single tongue-and-groove interlock

Panel Facings

Exterior Face: Stucco-embossed, G-90 galvanized and/or AZ-50 aluminum-zinc coated steel in 24 Ga. and 22 Ga.Interior Face: Stucco-embossed, G-90 galvanized, and/or AZ-50 aluminum-zinc coated steel in 26 Ga., 24 Ga., and 22 Ga.

Orientation Longitudinal to the Building WidthCF30A Insulated Metal Wall PanelsPanel Thickness 2", 2-1/2", 3", 4"Panel Width 24", 30", 36"Panel Length 8'-0" to 32'-0"Joint Configuration Offset double tongue and groove with extended metal shelf for positive face fastening

Panel Facings

Exterior Face: Stucco-embossed, G-90 galvanized and/or AZ-50 aluminum-zinc coated steel in 22 Ga.Interior Face: Light Mesa profile, stucco-embossed, G-90 galvanized, and/or AZ-50 aluminum-zinc coated steel in 26 Ga., 24 Ga., and 22 Ga.

Orientation Horizontal or Vertical

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Environmental Product Declaration

Metl-Span® Insulated Metal Wall and Roof Panels CF42, CFR42, and CF30A According to ISO 14025

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Insulated Metal Panel Life Cycle Stages

Life Cycle Stages

The figure below provides an overview of stages included in the life cycle of an insulated metal panel. Additional information on each stage is detailed in this section.

Raw Materials

Material Content

Steel coil represents steel that has been rolled out into 22, 24, or 26 gauge sheet and hot-dipped galvanized.

Polyester polyol is one of the primary components of polyurethane and is typically produced by polymerizing propylene oxide and ethylene oxide.

Methylene diphenyl diisocyanate (MDI) is another primary component of polyurethane.

1,1,1,2-tetrafluoroethane (R-134a) is a hydrofluorocarbon often used as a refrigerant. At Metl-Span, this inert gas is used as a blowing agent to produce foam.

Catalysts are used to balance the reaction between polyester polyol and MDI that produces polyurethane

Energy, fuels, and water

Emissions to air, water, and soil (wastes)

Extraction and processing of raw materials

Insulated metal panel manufacture

Transportation

Panel distribution and installation

Panel maintenance

Panelend-of-life

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Environmental Product Declaration

Metl-Span® Insulated Metal Wall and Roof Panels CF42, CFR42, and CF30A According to ISO 14025

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Raw Material Extraction and OriginSteel and steel coil are traded on a global market. Hot-dipped galvanized steel used by Metl-Span is first coated for aesthetics and to provide weather protection before its use in insulated metal panels. The coated steel coil is sourced within North America.

The three primary chemicals used to produce polyurethane foam—namely polyester polyol, MDI, and R-134a—along with smaller quantities of two catalysts are all produced and sourced within the United States.

Raw Material AvailabilityAll raw materials are produced from fossil resources and thus of limited availability. Galvanized steel coil production, however, consumes around 0.1 kg of scrap steel per kilogram of output.

PackagingFoam sheets are layered between insulated metal panels before the panels are stacked on (OSB) oriented strand board and (EPS) expanded polystyrene underlayment and wrapped in polyethylene film. Depending on the facility, chipboard and/or oriented strand board are also used in packaging. These packaging represent waste codes 15 01 02 for plastic packaging and 15 01 03 for wooden packaging in the European Waste Catalogue. For the purposes of this LCA, packaging reuse is not modeled.

Base MaterialsComponent Material Availability Origin Mass CF42 Mass CFR42 Mass CF30AGalvanized coil

Steel coil, hot-dipped galvanized

Fossil resource, limited

Global 73% 76% 75%

Polyurethane foam

Polyester polyol Fossil resource, limited

US 12% 11% 12%

MDI Fossil resource, limited

US 13% 12% 12%

R-134a Fossil resource, limited

US 1.1% 1.0% 1%

Catalyst Fossil resource, limited

US 0.08% 0.13% 0.32%

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Environmental Product Declaration

Metl-Span® Insulated Metal Wall and Roof Panels CF42, CFR42, and CF30A According to ISO 14025

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Manufacturing

Insulated Metal Panels - Continuous Production Line (CPL)

Embossing Line Schematic

OneDimensionalView

ThreeDimensionalView

Transportation To Customer

Continuous Production Line Schematic

Decoiling

Exterior Facing

Interior Facing

Roll-Forming

Lamination Cooling

Cooling Stacking Packaging

Foam Injection

Cut-To-Length

(Conveyance)

One-dimensional view

Three-dimensional view

Embossing (Off-line) ProcessProcess Step Description1 Decoiler2 Embossing3 Recoiler

CPL Unit Process Descriptions

Metal FabricationMetal facings are embossed, trimmed, and rollformed into desired shape.

Foam Injection and Curing

Chemicals are metered and dispensed between two facings into foam and allowed to cure.

Panel Fabrication and Packaging

Panels are cut to size and placed into bundles for delivery

Continuous Production Line (CPL) for Foam PanelsProcess Step Description1 Decoiling of Facings2 Slitting3 Rollforming4 Foam Injection5 Lamination6 Saw (Panel Cut to Length)7 Panel Cooling8 Bundle Packaging

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Environmental Product Declaration

Metl-Span® Insulated Metal Wall and Roof Panels CF42, CFR42, and CF30A According to ISO 14025

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Insulated Metal Panels - Discontinuous Production Line (DPL)

Embossing Line Schematic

OneDimensionalView

ThreeDimensionalView

One-dimensional view

Three-dimensional view

Decoiling Slitting Cut To Length Roll Forming(Pro�ling)

PanelFabrication

Foam Injection& Curing

Packaging Transportation To Customer

Cut To Length(Sawing)

Stacking OfPanels

Embossing (Off-line) ProcessProcess Step Description1 Decoiler2 Embossing3 Recoiler

DPL Unit Process Descriptions

Metal FabricationMetal facings are embossed, trimmed, and rollformed into desired shape.

Foam Injection and Curing

Chemicals are metered and dispensed between two facings into foam and allowed to cure.

Panel Fabrication and Packaging

Panels are cut to size and placed into bundles for delivery

Discontinuous Production Line (DPL) for Foam PanelsProcess Step Description1 Decoiling of Facings2 Slitting3 Rollforming4 Foam Injection5 Lamination6 Saw (Panel Cut to Length)7 Panel Cooling8 Bundle Packaging

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Environmental Product Declaration

Metl-Span® Insulated Metal Wall and Roof Panels CF42, CFR42, and CF30A According to ISO 14025

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Metl-Span insulated panels are produced by injecting Class I liquid urethane foam between sheets of coated metal. The foam undergoes a chemical reaction which causes it to expand inside the cavity between the sheets, completely filling the space and bonding the foam to the metal surfaces. The result is a single, integrated unit that offers consistent thermal values, functions as the air/water/vapor barrier, and does not contribute to insect/rodent infestation. This process allows the production of insulating panels in a wide range of sizes, styles, colors and coatings to suit different applications.

The life cycle assessment conducted for this EPD accounts for blowing agent emissions to atmosphere during manufacturing. Scrap panels from manufacturing are separated into metal and foam. Eighty-eight percent of scrap steel is assumed to be recycled (based on Steel Recycling Institute 2010 recycling rates) and the remainder landfilled. Scrap foam is ground up, leading to the release of blowing agent trapped in the foam, and sent to landfill. Packaging waste from inbound raw material transport is not considered.

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Environmental Product Declaration

Metl-Span® Insulated Metal Wall and Roof Panels CF42, CFR42, and CF30A According to ISO 14025

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IMP Production LocationInsulated metal panels covered by this EPD are manufactured in one to seven of Metl-Span’s locations according to the table below. Panels are then shipped an average of 650 miles via flatbed truck to the installation site.

Health, Safety, and Environmental Aspects during ProductionMetl-Span continually strives for world class performance in safety and quality and has established Environmental, Health & Safety programs and policies designed to ensure all applicable local, state and federal regulatory requirements are met or exceeded. Metl-Span is committed to ongoing waste reduction activities with the goal of minimal waste to landfill in the coming years.

Transport to Installation

Finished panels are shipped on average 650 miles on a flatbed truck to an installation site.

Transport to InstallationParameter Value UnitsVehicle type Flatbed truckFuel consumption 5.7 miles per gallonDistance 650 milesCapacity utilization 67% %Bulk density of transported products 9-12 lbs. / sq. ft.

Metl-Span IMP Production LocationProduct Indiana Nevada Texas Virginia

(Prince George)Virginia

(Colonial Heights)Illinois

CF42CFR42CF30A

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Environmental Product Declaration

Metl-Span® Insulated Metal Wall and Roof Panels CF42, CFR42, and CF30A According to ISO 14025

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Installation

Interior Face

Exterior Face

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Environmental Product Declaration

Metl-Span® Insulated Metal Wall and Roof Panels CF42, CFR42, and CF30A According to ISO 14025

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Base Condition

Figure 2: Example IMP Wall Installation Guidelines

Framed Opening Condition

STRUCTURALSUPPORTBY OTHERS

4" x 3/4" - 14 GA.4 HOLE CF CLIP

CLIP FASTENERS

SEALANT TAPE

URETHANE SEALANT

GLAZING, FRAMING,AND PERIMETER

SEALANTBY OTHERS

1/8" RIVETS AT12" O.C.

EDGE COVERFLASHING

HEAD FLASHINGWITH GUTTER

METL-SPANINSULATED PANELMETL-SPAN

INSULATED PANEL

BASE ATTACHMENTANGLE BY OTHERS

CONC. FASTENERSBY OTHERS

WIPER GASKET

CLIP FASTENERS

4" x 3/4"- 14 GA.4 HOLE CF CLIP

SEALANT TAPE

URETHANE SEALANT

BASE EXTRUSION

FIELD DRILL 3/8"WEEP HOLES AT

24" O.C. MAX

EXTRUDEDSPLICE BAR

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Environmental Product Declaration

Metl-Span® Insulated Metal Wall and Roof Panels CF42, CFR42, and CF30A According to ISO 14025

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1/4-14 x 1 1/2" HWH TEK II SELF-DRILLSCREW AT EACH HIGH

MESA 4" O.C.

CLIP SEALANT TAPEEND LAP SEALANT TAPE

#14 x 7/8" HWHSELF- DRILL SCREW

AT 8" O.C.

RIDGESTRUCTURAL

BY OTHERS

2 OR 3 REQUIREDPER CLIP.

CFR PANEL CLIPAT EACH PANEL

SIDELAP

EXTERIOR RIDGE FLASH

SEALANT AT SIDE JOINT

BUTYL VAPOR SEALANT

RIDGECLOSURE

BACK-UP PLATE FACTORYINSTALLED AT EA. HIGHMESA 4" O.C.

METL-SPAN CFRINSULATED

ROOF PANEL

INTERIOR RIDGEFLASHING

LOOSE-FILLINSULATIONBY OTHERS

ENDLAP SEALANT TAPE

6" MINIMUM1'-6" MAXIMUM

Panel Connection at Joint

Figure 3: Example IMP Roof Installation Guide

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Environmental Product Declaration

Metl-Span® Insulated Metal Wall and Roof Panels CF42, CFR42, and CF30A According to ISO 14025

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Metl-Span insulated panels are installed as a system over a new or existing structural steel support, such as wall or roof framing. Correct installation requires the use of butyl sealant and specifically designed fasteners, which are delivered with the panels. Figures 2 and 3, on the previous pages, illustrate the installation process. After the panels are in place, framed openings, flashing, trim, molding and other exterior components can be installed. (Note: Performance modeling is limited to the Metl-Span panel/sealant/fastener system and does not include framing and other wall/roof/ceiling elements or aesthetic elements such as aluminum extrusions often used with CF30A panels. Energy needed to operate any cranes or other installation equipment, however, is included.) Installation assumptions are detailed in the table below.

Scrap panel from installation is broken down by hand with 88% of scrap steel is recycled and the remainder sent to landfill along with 100% of scrap foam. Panel packaging is also disposed of at this stage. While some of the packaging materials can be reused, all packaging waste is assumed to be sent to landfill for the purposes of this LCA and landfill gas recovered to generate electricity.

Safety and Environmental Protection in Installation

Metl-Span complies with all federal, state and local health and safety requirements. Our employee safety policies, practices and systems meet or exceed OSHA standards.

InstallationParameter CF42 CFR42 CF30A UnitsInsulated metal panel installed 1,500 1,500 1,500 sq. ft. / D.U.Ancillary materials for installation

Steel sheet 270 78 17 kg / D.U.Butyl sealant 38 15 57 kg / D.U.Polyurethane sealant 0 1.1 15 kg / D.U.Rubber 0 0 30 kg / D.U.

Energy for installationElectricity (US grid) 5.3 33 6.9 kWh / D.U.Propane 650 0 630 MJ / D.U.

WastesScrap panel 7.5 7.5 7.5 sq. ft. / D.U.Wood-based packaging 77 72 77 kg / D.U.Plastic packaging 47 48 60 kg / D.U.

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Environmental Product Declaration

Metl-Span® Insulated Metal Wall and Roof Panels CF42, CFR42, and CF30A According to ISO 14025

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Use

Once installed, insulated metal panels do not directly consume energy, and require little to no maintenance. There are no parts to repair or refurbish.

Service LifeMetl-Span insulated wall and roof panels are available with paint finish warranties of up to 40 years, which means that these panels need be replaced only once to achieve 60-year coverage, in accordance with the PCR. In modeling this performance, all non-use phase impacts were scaled up to cover manufacturing, installation and removal, disposal, reuse and recycling of the original panel plus a replacement panel (note that per the PCR, only half the impacts of the replacement panel are allocated to the product system). There are documented examples of Metl-Span panels in use for over 40 years that, with minimal maintenance, have retained their original appearance and are performing to their original specifications. Depending on local environmental conditions, their projected life could span 50 to 60 years and beyond.

Effects on the Environment and HealthOff-gassing of the blowing agent is not a concern because the foam is encased between two metal sheets, which prevent diffusion by air.

Building OperationWhile use of the panels can affect building operational energy use, building operation is not considered.

End-of-Life

At the end-of-life, the panels are broken down by hand (deconstruction); since only manual labor is involved, no environmental impact is associated with this step. Wastes are then transported 20 miles to disposal. Eighty-eight percent of scrap steel is recovered per Steel Recycling Institute rates. The remaining scrap steel is landfilled, along with all the foam. At the landfill, any blowing agent remaining in the foam is released to the atmosphere.

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Environmental Product Declaration

Metl-Span® Insulated Metal Wall and Roof Panels CF42, CFR42, and CF30A According to ISO 14025

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Requirements for the Underlying Life Cycle Assessment

For this EPD, a “cradle-to-grave with options” life cycle assessment (LCA) was conducted. The analysis was done according to the product category rule (PCR) for insulated metal panels and followed LCA methodology guidelines laid out in the ISO 14040/14044 standards, as well as in the EN 15804 standard for construction products. As such, EPDs of construction products may not be comparable if they do not comply with the same PCR or ISO standards.

While the intent of the PCR is to limit variability among analyses, there may still be differences among EPDs that comply with the same PCR (e.g. due to differences in system boundaries, background data, etc.). Consequently, differences among EPDs are not guaranteed for comparative purposes.

Functional Unit

Per the PCR, a declared unit of coverage of 1,000 sq. ft. with a metal product for a building reference service life of 60 years was chosen for the analysis. Since the panel is assumed to have a 40-year reference service life, it will have to be replaced once during the 60-year timeframe. Results are accordingly scaled to account for this replacement, with 50% of the replacement panel’s impacts allocated to the product system.

System Boundaries

A cradle-to-grave life cycle analysis was conducted, from extraction of natural resources to final disposal. Within these boundaries the following stages were included:

> Product Stage (A1 – A3): Raw material supply, inbound transport of raw materials to manufacturing facility, manufacturing

> Construction Process Stage (A4 – A5): Outbound transport of finished product to construction site, construction installation process

> Use Stage (B1 – B5): Use, maintenance, repair, replacement, refurbishment

> End-of-Life Stage (C1 – C4): Deconstruction / demolition, transport to disposal facility, waste processing, disposal

Building operational energy and water (B6 and B7) used were not assessed, nor were the construction and maintenance of capital equipment (e.g., production equipment). Additionally, human labor and employee commute were not included in the analysis.

Period under ConsiderationProduction data represent operational activities during Metl-Span’s fiscal year from July 1, 2010 to June 30, 2011. Annual average values were used.

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Geographic CoverageMetl-Span's manufacturing facilities are located in Indiana, Nevada, Texas, Mississippi, Illinois, and two locations in Virginia. As such, the geographical coverage for this study is based on North American (NA) system boundar-ies for all processes and products. Results for panels produced in multiple locations are presented as production weighted averages of the different locations.

Cut-Off Criteria

The cut-off criteria for including or excluding materials, energy and emissions data of the study were as follows:

> Mass – If a flow is less than 1% of the cumulative mass of the model it may be excluded, providing its environmental relevance is not a concern.

> Energy – If a flow is less than 1% of the cumulative energy of the model it may be excluded, providing its environmental relevance is not a concern.

> Environmental relevance – If a flow meets the above criteria for exclusion, yet is thought to potentially have a significant environmental impact, it was included. Material flows which leave the system (emissions) and whose environmental impact is greater than 1% of the whole impact of an impact category that has been considered in the assessment must be covered. This judgment was made based on experience and documented as necessary.

These criteria were applied to factory supplies such as lubricants and tape, as well as a catalyst. The sum of the excluded material flows was determined not exceed 5% of mass or energy and is not anticipated to exceed 5% of environmental relevance.

Allocation

Since only facility level data were available, input and output flows were allocated among each facility’s co-products to determine the flows associated with the three specific products analyzed. Allocation of materials was done on a mass- or volume-basis as appropriate.

Metal scrap generated during manufacturing, installation, and at end-of-life was addressed with the avoided burden modeling approach. This approach allocates as much of the burden of a primary material’s production to the subsequent life cycle as can be recovered through recycling taking into account collection rates and recycling efficiencies (“EoL credit”). To be consistent with the Worldsteel dataset for galvanized steel coil, scrap steel input is given a burden based on the Worldsteel ”value of scrap” model which utilized the modeling approach described in a study of recycling methodologies. This “value of scrap” is used as the upstream burden of any scrap input in the production of steel coil, and its inverse is consistently used throughout the study to provide credit for any scrap steel generated.

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Environmental Product Declaration

Metl-Span® Insulated Metal Wall and Roof Panels CF42, CFR42, and CF30A According to ISO 14025

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Background Data

The LCA model was created using the GaBi 5 Software system for life cycle engineering, developed by PE INTERNATIONAL AG. The GaBi 2011 LCI database provides the life cycle inventory data for several of the raw and process materials obtained from the background system. North American background data were used whenever possible; if such data were not available, European data were used as a proxy.

The Worldsteel global average data were used for galvanized steel coil background data, with coil coating data obtained from the Metal Construction Association (MCA), of which Metl-Span is a member.

Life Cycle Assessment Results and Analysis

Life Cycle Impact Assessment

Cradle-to-grave life cycle impact assessment results are shown for both TRACI 2.0 and CML characterization factors. These results are relative expressions and do not predict impacts on category endpoints such as Human Health or Ecosystem Quality, the exceeding of thresholds, safety margins, or risks.

With respect to global warming potential, no credit was given for the sequestration of biogenic carbon during the growth of plants used in plant-derived packaging materials. Any carbon temporarily sequestered during the use of bio-based materials is assumed to be re-released to the atmosphere upon their decomposition. Since the life-time of plant-derived packaging materials is shorter than the 100 year time horizon of this impact category (GWP 100), biogenic carbon was excluded from the global warming potential calculations.

Life Cycle Impact Assessment: TRACI 2.0Impact Category Units CF42 CFR42 CF30AGlobal warming potential (GWP) kg CO2-eq. 82,000 80,000 100,000Ozone depletion potential (ODP) kg CFC11-eq. 2.1E-04 2.3E-04 2.7E-04Acidification potential (AP) kg H+ mol-eq. 830 830 1000Eutrophication potential (EP) kg N-eq. 1.1 1.1 1.3Smog formation potential (SFP) kg O3-eq. 200 200 250

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Life Cycle Impact Assessment: CML 2001 – November 2010Description Units CF42 CFR42 CF30AGlobal warming potential (GWP) kg CO2-eq. 82,000 80,000 100,000Ozone depletion potential (ODP) kg R11-eq. 1.2E-02 1.2E-02 1.6E-02Acidification potential (AP) kg SO2-eq. 16 16 20Eutrophication potential (EP) kg Phosphate-eq. 1.7 1.7 2.1Photochemical oxidation potential (POCP) kg Ethene-eq. 2.0 2.0 2.5Abiotic depletion potential (ADP) – elements kg Sb-eq. 0.03 0.03 0.035Abiotic depletion potential (ADP) – fossil fuels MJ 74,000 73,000 98,000

CF42 Impact Results

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CF30A Impact Results

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Energy and Material Resources

Primary energy resources, secondary material, and water use are presented below. Since no secondary fuels are associated with insulated metal panels, this category is not shown.

Energy and Material Resource Use per Declared UnitPrimary energy, renewable [MJ]

Primary energy, non-renewable [MJ]

Secondary material[kg]

Water use[m3]

CF42

Total 5,600 82,000 160 930Raw materials 3,900 76,000 130 740Transport to facility 63 6,500 0 18Manufacturing 300 2,100 0 55Transport to install 19 2,000 0 5.5Installation 270 13,000 29 100Transport to disposal 1 65 0 0.18Waste processing 1,000 -18,000 0 -3.4Disposal 23 540 0 18

CFR42

Total 5,600 81,000 160 930Raw materials 4,000 83,000 150 730Transport to facility 66 6,800 0 18Manufacturing 340 2,000 0 95Transport to install 24 2,500 0 6.8Installation 120 4,400 8.1 61Transport to disposal 1 64 0 0.18Waste processing 1,000 -18,000 0 -3.4Disposal 22 520 0 17

CF30A

Total 6,500 110,000 180 1,300Raw materials 4,600 100,000 180 910Transport to facility 77 8,000 0 22Manufacturing 240 2,000 0 18Transport to install 31 3,200 0 8.8Installation 320 13,000 1.7 290Transport to disposal 1 76 0 0.21Waste processing 1,100 -20,000 0 -3.8Disposal 31 720 0 24

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CF30A

CFR42

CF42

-37,500 0 37,500 75,000 112,500 150,000

Primary Energy, Total

CF42 Renewable Primary Energy

CF30A RenewablePrimary Energy

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Renewable primary energy is also broken down into primary energy resources used as raw materials and primary energy resources excluding resources used as raw materials. Since consumption of renewable primary energy resources used as raw materials is exclusively due to packaging materials and takes place during raw materials supply, this category is not broken down by life cycle stage. Around 28% of total renewable primary energy is associated with renewable primary resources used as raw materials.

Waste and Output Flows

Additional environmental information, including hazardous, non-hazardous, and radioactive waste disposed; materials for recycling; and materials for energy recovery are shown below.

Renewable Primary Energy Breakdown per Declared Unit

ProductRenewable primary energy used as raw materials [MJ]

Renewable primary energy, excluding those used as raw materials [MJ]

Renewable primary energy, total [MJ]

Chipboard OSB PlywoodCF42 28 1,500 180 3,900 5,600CFR42 32 1,400 190 4,000 5,600CF30A 46 1,500 200 4,700 6,500

CF30A Non-Renewable Primary Energy

CF42 Non-Renewable Primary Energy

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Since no reused components or exported energy are associated with an insulated metal panel’s life cycle, these categories are excluded. Additionally, waste is assumed to be recovered or sent to landfill so no materials are available for energy recovery.

Interpretation

Above results represent a cradle-to-gate with options assessment of the environmental performance insulated metal panels produced by Metl-Span. The assessment was conducted for one declared unit, or coverage of 1,000 sq. ft. with a metal product for a building reference service life of 60 years. Since the panel is assumed to have a 40-year reference service life, it is replaced once during the 60-year timeframe and results are accordingly scaled to account for this replacement. The results are consistent with metal panel characteristics with panels using thicker gauge steel and denser foam corresponding to higher environmental impact.

Global warming potential is the only environmental impact category for which panel production drives environmental performance due to manufacturing R-134a emissions. One hundred percent of the R-134a consumed during production is assumed to be (eventually) released to the environment, either during the panel production or from the disposal of foam scrap and the panel at end-of-life. While the exact amount of R-134a emitted during panel production may vary among facilities, lower emissions during manufacturing will only affect the panel’s cradle-to-gate global warming potential—not its cradle-to-grave global warming potential.

In all other impact categories, insulated metal panel environmental performance is driven primarily by raw materials—in particular steel, followed by R-134a, MDI, and polyester polyol due to their high mass contribution to the product. In cases where installation also has a high impact, it is due to the inclusion of raw materials used by installation components such as fasteners and flashing in this stage.

Waste and Other Flows per Declared Unit

Product Hazardous waste disposed [kg]

Non-hazardous waste disposed [kg]

Stockpile goods [kg]

Radioactive waste disposed [kg]

Materials for recovery [kg]

CF42 35 12 7,700 2.6 77CFR42 36 12 7,700 2.6 79CF30A 41 14 9,900 3.3 90

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Raw material inbound transportation accounts for a smaller contribution to overall impact. The other two transportation stages (i.e., finished product to the building site and deconstructed panels to final disposal) have negligible contribution according to all impact metrics. Finally, the product systems are assumed to receive credit for recycling 88% of steel waste at end-of-life. Although the life cycle is also credited with recycling scrap steel at the manufacturing and installation stages, these credits are smaller compared to the environmental impact of those stages.

Any credit received by the product system from scrap steel recovery is represented as a negative burden in the results because the recovered scrap replaces the production of virgin material and thus enables avoidance of that production burden. Additionally, the product system receives energy credit for bio-based materials used for packaging, including chipboard, oriented strand board, and plywood. This credit occurs at the packaging’s end-of-life when it is disposed in a landfill after the panels are installed on a building. At the landfill, the materials decompose, leading to the production of landfill gas. If the landfill gas is captured, it can be combusted to generate electricity and the associated product system credited with the avoided production of electricity. No burden or credit is assigned to biogenic carbon.

No impact is associated with the use stage because the panels do not consume energy; additionally little to no maintenance is required to ensure the panels last a minimum of 40 years. At the end of the panel’s reference service life, the panels may require replacement in order to fulfill the 60-year building reference service life (as specified by in declared unit). Panel replacement will involve deconstructing and disposing the old panels, as well as producing and installing the new panels. The impacts of these processes, however, are assigned to other life cycle stages as appropriate.

A declared unit, rather than a functional unit, is chosen for this LCA because the panels evaluated serve different functions and are not meant to be compared. It is possible, however, that the EPD containing these results will ultimately be used for comparative purposes with EPDs produced by other manufacturers. In such cases, it should be noted that even though the EPDs comply with the same PCR, there may still be differences that may affect comparison results.

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Additional InformationContact Metl-Span at their headquarters or visit METLSPAN.COM

LCA and EPD Development

The LCA and EPD were prepared by PE International, Inc. and Merge Marketing Group.

ReferencesISO 14040 ISO 14040:2006-10, Environmental management – Life cycle assessment – Principles and framework (ISO 14040:2006); German and English version EN ISO 14040:2006

ISO 14044 ISO 14044:200610, Environmental management – Life cycle assessment – Requirements and guidelines (ISO 14044:2006); German and English version EN ISO 14044:2006

EN 15804 EN15804:2012, Sustainability of construction works – Environmental product declarations – Core rules for the product category of construction products.

SRI “Steel Recycling Rates,” Steel Recycling Institute Available: http://www.recycle-steel.org/en/ Recycling%20Resources/Steel%20Recycling%20Rates.aspx.

Contact Info

PIONEERING INSULATEDMETAL PANEL TECHNOLOGY

1720 Lakepointe DriveSuite #101Lewisville, Texas 75057Toll-free: 877.585.9969Tel: 972.221.6656Fax: 972.420.9382Email: [email protected]: metlspan.com

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