Process information
| Key Data Set Information | |||
| Location | PL | ||
| Reference year | 2023 | ||
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| Use advice for data set | Scope: The LCA is based on consideration on all SOLBET Group plants: SOLBET Sp. z o.o.: Solec Kujawski plant, Podnieśno plant, Rurka plant, SOLBET LUBARTW S.A.: Lubartw plant, SOLBET KOLBUSZOWA S.A.: Głogw Małopolski plant, Lipie plant, SOLBET STALOWA WOLA S.A.: Stalowa Wola plant, and the data basis is 2021. System boundary: Type of EPD according to EN 15804: cradle to gate with options, modules C1–C4, and module D. The following modules are declared: A1–A3, C, D and additional modules: A4 + A5 +B1. Production - Modules A1-A3 The product stage includes: Raw material supply (A1) Transport to the manufacturer (A2) Manufacturing (A3), including provision of all materials, products and energy, as well as waste processing up to the end-of-waste state. Packaging is also considered in this module. Construction stage - Modules A4-A5 The construction process stage includes: Transport to the construction site (A4): This module considers 100 km truck transport to the site. The transport distance can be modified project-specific if required by linear scaling. Thermal treatment of packaging material (A5) where the resulting credits are declared in module D. Offcuts were not taken into account, as they strongly depend on the building context and can be estimated approximately via the declared values for the production stage. The installation of the products themselves is usually done manually (load-free). Use stage (B1) Carbonation of reactive product components (e.g. CaO and MgO) are considered in this module. A carbonation rate of 98.97 % is assumed, P. Walczak / SOLBET Research Center Department, 2022. End-of-life stage– Modules C1-C4 The end-of-life stage includes: Module C1: Mechanical dismantling (excavator). Module C2: Truck transport to EoL (50km). If necessary, transport distance can be adapted to building level. Module C3: Construction waste processing (shredding) and material recycling as filling material (incl. credits for substitution of gravel in Module D) assuming 5 % recycling losses are sent to landfill. The end of waste status is reached after shredding. This module also considers carbonation at the end of life. Reuse, recovery or recycling potential beyond system boundary - Module D This module considers material credits from saved expenditures through the substitution of gravel as backfill material (module C3). It also includes the credits of the thermal and electrical energy generated in Module A5 due to the thermal treatment of packaging. Avoided burdens have been calculated by the inversion of residual grid mix and thermal energy from natural gas, using European datasets. | ||
| Technical purpose of product or process | Autoclaved aerated concrete elements are using in all kinds of construction and non-construction walls: single-layer wall, multi-layer wall, cavity wall, retaining wall and basements, and in all external elements with a protected face surface. | ||
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| General comment on data set | The subject of the declaration are non-reinforced aerated concrete masonry elements of various sizes and density classes, manufactured using the autoclaving process. SOLBET products are used to construct load-bearing and non-loadbearing masonry structures in all types of walls, including single leaf, cavity, partitions, retaining, basement and external walls with a covered facing surface. Elements of autoclaved aerated concrete should be classified as an lightweight concrete. SOLBET autoclaved aerated concrete (AAC) elements are produced according to EN 771-4:2011+A1:2015 - Specification for masonry units - Part 4: Autoclaved aerated concrete masonry units. All Autoclaved Aerated Concrete elements in SOLBET group are produced in system 2+ in Category I in accordance with EN 771-4. All AAC products produced in SOLBET group have DoP according to regulation 305/2011 and the CE market. Autoclaved Aerated Concrete in SOLBET group is produced according to EN 771-4:2011+A1:2015 definition: the AAC is "manufactured from hydraulic binders such as cement and/or lime, combined with siliceous based fine material, cell generating material and water and cured with high pressure steam in autoclaves". | ||
| Copyright | Yes | ||
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| Data set valid until | 2028 | ||
| Technological representativeness | |||
| Technology description including background system | Sand is a main raw material which is used in production of Autoclaved Aerated Concrete. Sand is milling with water, gypsum and crushed AAC in ball mills. After that is dosing with returns, cement, lime, additional water and small amount of aluminium powder to the mixer. The mass is casting and aluminium powder reacts with calcium hydroxide and water to form hydrogen. The hydrogen gas foams and increase the volume of the raw mix creating bubbles, causing it to rise. At the end of the rising process, the hydrogen escapes into the atmosphere. Due to this fact the AAC has a porous structure. After this stage the cake can be cut to the final dimensions and placed in autoclaves, where the hydrothermal conditions is used to curing the AAC cakes. During the steam pressure hardening process, the pressure 11 – 12 bars is used, when the quartz sand reacts with cement and lime to form the calcium silicate hydrates – mainly tobermorite. After autoclaving process the AAC blocks are packing on the automatically packaging line and after that are sending to clients. If some blocks are damaged in the packing process, are crushed and returned to the production process. Technical data: The basic functional properties of wall elements made of autoclaved aerated concrete, produced in the SOLBET capital group, are presented in the table below. Declared unit: The declared unit is 1 m3 of non-reinforced aerated concrete. The average density per product with moisture content declared at factory gate is 663 kg/m3. The average density according to EN 771-4:2011+A1:2015 in dry mass is 515 kg/m3. | ||
Modelling and validation
| Subtype | average dataset | ||||
| LCA methodology report | |||||
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| Documentation of data quality management | |||||
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| Compliance Declarations | |||||
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Quality compliance
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| Compliance |
Compliance system name
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Approval of overall compliance
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Nomenclature compliance
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Methodological compliance
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Review compliance
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Documentation compliance
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Quality compliance
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Administrative information
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| Time stamp (last saved) | 2023-10-24T00:00:00 |
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| Publication and ownership | |
| UUID | 27294b53-c212-4c35-bb30-3dbdf9fca0f9 |
| Data set version | 00.01.000 |
| Registration authority | |
| Registration number | EPD-SOL-20230257-CBD1-EN |
| Owner of data set | |
| Copyright | Yes |
| License type | Free of charge for all users and uses |
| Access and use restrictions | None |
Environmental indicators
Indicators of life cycle