Designing for Composites Sustainability

Design for Sustainability

Gale Tedhams, Owens Corning

Ken Schmidtchen, Kalwall Corp.

Matt Gindlesparger, Fresh Air Building Systems, LLC.

Bob Moffit, Ashland

October 13-16, 2014

Orange County Convention Center

Orlando, FL

Panelists • Gale Tedhams, is the Director of Sustainability, Product and Supply Chain for Owens

Corning. responsible for leading the company’s global sustainability strategy with a focus on product and supply chain sustainability and on Owens Corning’s aspiration to being a net positive company.

• Ken Schmidtchen is the Engineering Manager at Kalwall Corporation. Kalwall produces a translucent composite sandwich panel for the architectural and construction industry. As Engineering Manager, Ken is responsible for product development, building code compliance, testing and technical sales support as well as coordinating the sustainability efforts of the firm.

• Matt Gindlesparger is Chief Technical Office at Fresh Air Building Systems LLC, a company that provides plant based wall systems which integrate into a buildings HVAC system to improve indoor air quality, reduce energy consumption and provide fresh air from within. Fresh Air Building Systems, LLC used molded fiberglass composite assemblies for a majority of its products. Matt is also a visiting assistant professor of architecture at Philadelphia University where his teaching and research focus on advanced building systems and next generation building technologies.

• Bob Moffit is Product Manager at Ashland - a supplier of Polyesters, Vinylesters and Gelcoats. Bob is responsible for Ashland resins that are used to produce composites for the building and construction market, including Ashland's line of bio and recycle containing Envirez resins. Bob is chair of the ACMA's Green Composite Council.

Session

• Interactive

– Turn ON your phones

• Sustainability Defined

• A Manufacturer’s View

• Leveraging Materials Towards Sustainable

Products

• Sustainability Resources

Text Polling

Text Polling

Capitalization doesn’t matter, but spaces and spelling do

Sustainability

Gale Tedhams, Owens Corning

Copyright © 2014 Owens Corning All Rights Reserved.

First Question:

• In your view, what describes Sustainability

in your business today?

– It’s a hurdle

– It’s an opportunity

– It’s a business strategy

– It’s just a buzz word

– Has not come up

Sustainability

• The Ability to Sustain

– your Business

– your Prosperity

– the Resources required

– People (employees, stakeholders)

– your Communities

Flourish Forever

Copyright © 2014 Owens Corning All Rights Reserved.

Macro Trends in the World..

Legislation/Policy

Technological change

Population Growth Climate Consciousness Energy Type, Cost, Security

Globalisation

Technological change

Economic

Growth

Socio-

Economic

Eco-

Efficiency

Sustainability

Socio-

Environmental

Social

Progress

Sustainability

Company

Government

Customers Competitors

Shareholders

Old World:

Sources of Pressure

Today: Diverse Stakeholders

10/17/2014

Source: Green to Gold, Esty/Winston 2006

Regulators

NGOs Banks

Shareholders

Insurers

B2B

Buyers

Competitors Suppliers

Capital

Markets

“The Future”

(Kids)

Communities

Consumers

Rulemakers &

Watchdogs

Business

Partners

& Competitors

Consumers &

Community

Investors &

Risk

Assessors

CEO

Peers

Employees

Industry

Assoc.

“Plaintiff’s

Bar”

Politicians

Company Idea

Generators

& Opinion

Leaders

Media

Think

Tanks

Academia

Common Themes

• Provide for Energy Reduction or Renewables

• Conserve Water or Improve Quality

• Conserve Natural Resources

• Reusable or Recyclable at End of Life

• Avoid Toxic Materials or Emissions

• Contribute to Safety and Health

• Ethics and Business Conduct

• Transparency

• Philanthropy

• Community Vitality

• Lightweight

• Durable

• Corrosion resistance

• High strength

• Fatigue resistant

• Non-conductive

• Design flexibility

Applications Properties

Composite Attributes that Enable Sustainable Solutions

• Energy efficiency

• Durability

• Reduced emissions

• Safety

• Conservation of materials

Sustainable

Attributes

Providing Opportunities

for Composites Urban

Infrastructure

Clean Water

Clean Energy

Industrial Light

Weighting

Housing & infrastructure to a growing

population in developing and third world

countries.

Basic infrastructure to deliver clean water

to an excess of 7 billion people.

Production of energy with no emissions of

CO2 (wind, tidal, solar & geothermal)

Reducing the weight of modes of

transportation for efficiency

What is your market

For instance: Transportation, Building

Materials, Infrastructure, Aerospace,

Automotive, Aircraft, Marine, etc…..

Market/Customer Driven

• Automotive - Fuel economy, Recyclability

• Construction - Green building

• Infrastructure – Durability

• General -- Risk Mitigation, Transparency,

Cost savings, Life Cycle Impact

• Have you been asked by customers or

potential customers for information about a

Sustainability Program in your company or

the sustainability of your business?

– Yes

– No

• What was your first reaction to being

asked about your Company Sustainability

Program?

– Yes, we have a program

– No, what is it?

– No, we don’t have a program

– Quick, call John Busel and ask him what to

say!

A Manufacturer’s Point of View

Ken Schmidtchen, Kalwall Corp.

Two Areas of Focus

• What the

product is

–Engineering

–Operations

–Materials

–Process

• What the

product does

–Consumption

–Air Quality

–Weight

–Other

Other Benefits

Drivers

• Corporate Stewardship

• Customer Request

CORPORATE STEWARDSHIP

Stewardship

• Doing the right thing

• Environment

• Employees

• Customers

Environment

• Process Improvement

• Recycling

• Material Usage

• Energy Usage

What environmental or social

aspects are you taking action on?

For instance: Recycling, Energy

efficiency, Water conservation,

Reduced emissions, worker

safety, Community volunteer,

etc….

Employees

• Wellbeing

• Peace of Mind

• Pride

• Community Outreach

• Does your company have a safety

program that exceeds regulatory

standards for worker health and well

being?

CUSTOMER MOTIVATION

What they want

Customers

• Supplier accountability

• Material

• Environmental impact

• End of Life

• Transparency

Customers

• Impact of their decision

– Current use

– Future

– Ultimate fate

TRANSPARENCY

Alphabet Soup

Transparency Programs

• Drivers of Product Transparency

– LEED

– Living Building Challenge

– Others: CalGreen, IgCC, etc

• Product Transparency Programs

– Green Screen

– Cradle to Cradle

– Environmental Product Declaration (EPD)

– Health Product Declarations (HPD)

– Product Transparency Declaration (PTD)

WHY BOTHER?

What’s in it for me?

Benefits

• Savings

• Image

• Sales

• Environment

Savings

• Productivity

• Efficiency

• Reduced Waste

Image

• Responsible

• Forward thinking

• Concerned

Sales

• Willing Audience

• Product

– Process

– Benefits

Heads Up!

• Avoid “Greenwashing”

• Better to say:

– no,

– not yet

– “we are looking into it”

Composite Benefits

• Efficiency

• Durability

• Design Freedom

Product Benefits

• Specific performance benefits

– Meet sustainable intent

– Reduce, Reuse, Recycle

– User benefits

Why Bother?

• Customers want

• Codes / Designs may require

• Sustainability pays

Leveraging Material Strengths

Towards Sustainable Products

Matt Gindlesparger

Fresh Air Building Systems, LLC.

Air Pollution

World Health Organization lists air pollution as the world LARGEST

single environmental health risk. (WHO, 2014)

Air Quality and Worker

Productivity

Source of Productivity Gain Strength of Evidence

Respiratory disease Strong $6-$14 billion

Allergies and Asthma Moderate to Strong $1-$4 billion

Sick Building Syndrome Moderate to Strong $10-$100 billion

Worker Performance Moderate to Strong $20-$200 billion

Total $37- $318 billion

Kibert, 2008: A study by Fisk and Rosenfeld in 1998 (updated in 2002).

US Annual Savings or

Productivity Gain

Have you been asked about

sustainability of your products?

•Yes

•No

Active Modular Phytoremediation

System : AMPS

• Plant Based Air

Filtration System

–Improves Indoor

Air Quality

–Energy Savings

–Brings Outdoors In

October 13-16, 2014

Orange County Convention Center | Orlando, FL

• Key Benefits

– Scalable

– Modular

– Integrated Systems

– Turn-key product

– Low Maintenance

Lab Scale DATA Acquisition - Aerosols,

Microbial Mechanisms, etc.

Zone Scale Public Safety Answering

Center II, Bronx NY.

Room Scale CBIS Lobby Installation /

Deployable testing panels

Single Pass VOC

Remediation Efficiency

(Aerosols Lab, Civil and

Environmental Eng.)

Modular and scalable

system design that

evolves with scientific

advances

HVAC System

integration

(Demonstration of

Energy Savings /

Health Benefits)

ARE YOU ABLE TO PROVIDE

INFORMATION TO YOUR

CUSTOMERS ABOUT PRODUCTS

REGARDING SUSTAINABILITY?

Question:

Market Drivers

• Client Demands for improved Indoor Air

Quality in buildings

• Passive Greenwall systems are gaining

popularity

• Seeking energy savings in buildings

Metrics

• >80% reduction of VOC’s from

the airstream

• >30% reduction in HVAC

system energy loads

• Benefits of biophilic effect

Material Selection

• Requirements

– Integral Components and Systems

–Low weight

–Modular

–Non-porous

–Code Standards and requirements for buildings

Exploded Cassette AssemblyScale 2"=1'-0"

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Sheet Size:

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Exploded Cassette Assembly

Cassette Shell*Cassette shell, Trim ring assembly and Cassette cap are permanently bonded together parts exploded for clarity

Cassette Mounting Pins

Mesh container

Growing media

Wicking structure

Plant

LED strip

LED wiring harness

Aluminum mounting angle for LED stripsembedded into trim ring assembly

Molded fiberglass Trim ring assembly

Cassette cap with integral slot for irrigation

Modular Cartridge Assembly

Molded Composites

• Benefits

– Allowance for complex geometry

– Light weight

– High strength to weight

– Finish surfaces is non-porous and cleanable

– Finish specifications meet Class I rating

– Production is compatible with modular components

Sustainability Resources

Bob Moffit, Ashland

Chair of ACMA’s GCC

Audience Poll

• What is going to keep you up at night after this session?

(Free form)

For instance:

– Sustainability

– Stewardship

– Transparency

– Liability

– Marketing claims

– Others?

Developing a Sustainability Plan

• Smart Steps to Sustainability

– Easy to understand steps: • Building knowledge; Defining Vision

• Setting Goals; Turning Strategy into Action

• Measurement and Continuous Improvement

• Sustainability Reporting

Standards for external sustainability report www.globalreporting.org/information/sustainability-

reporting

EPA Bulletin: 180/B-09/001

Global Sustainability

Reporting Initiative

Competitors • American Concrete Institute

http://www.concrete.org/topicsinconcrete/topicdetail/sustainability

· Resources, reports, and guidance on concrete sustainability

• The Aluminum Association http://www.aluminum.org/sustainability

· Resources and sustainability reports on aluminum

• World Steel Association http://www.worldsteel.org/steel-by-topic/sustainable-steel.html

· Resources and sustainability reports on steel

• American Iron and Steel Institute http://www.steel.org/Sustainability.aspx

· Resources and sustainability reports on steel

• Wood Products Council http://www.woodworks.org/sustainable-design/

· Resources for sustainable design

Responsible Care®

• Responsible Care: EHS&S performance

standard for facilities, processes and products.

– Product Safety Code of RC:

• Helps ensure safe, responsible, sustainable management of

chemicals through their life cycles

• Improve awareness of product risk thru the value chain

• Provide the public with access to product safety and

stewardship information

RC: Product Safety Code

Marketing Your Products

• Guidelines for ‘green’ marketing

– Cautions against unqualified claims such as

• Environmentally friendly

• Eco Friendly

– How to adequately qualify environmental

claims

– Appropriate use of certifications and seals of

approval

FTC: 16 CFR Part 260

Industry Resources

• ACMANET.ORG / Member Resources

– Compliance Tools & Stewardship Resources • Air emissions from composite manufacturing operations

• Bulk resin storage guidelines

• Chemical safety and regulation

• Conflict minerals

• Particulate matter emissions

• Permits for air emissions

• Glass fiber handling safety

• Composite industry workplace hazards

• Styrene odor management

Getting Involved

ACMA Green Composites Council

Sub-Committees:

• LCI / LCA

• Bio Products

• Recycling

• Product Transparency

• Education

Audience Poll

• What is one idea you will take action on

after this session? (free form)