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Process Data set: Aircrete Blocks Super (en) en

A more recent version of this data set exists in the database.

Most recent version of this data set:00.03.001

Key Data Set Information
Location GB
Geographical representativeness description Ireland
Reference year 2018
Name
Aircrete Blocks Super
Technical purpose of product or process This LCA is carried out for Mannok Aircrete blocks: Super. The constituent materials of the block comprises water, sand, cement, silt, lime, PFA, and aluminium The gross dry density of the Super block is 480 kg/m3. These light weight and high insulating value blocks are used to improve thermal performance of buildings. They are designed for use in external walls, rising foundation walls, internal partition walls and party walls between dwellings. The blocks are manufactured and tested in accordance with BS EN 771-4:2011+A1:2015 “Specification for masonry units. Autoclaved aerated concrete masonry units”. The strength and thermal conductivity values given in this EPD are those that are reported in the BBA certificates which can be downloaded at the following pages: https://www.mannokbuild.com/aircrete-thermal-blocks/mannok-aircrete-super/ The raw materials used in production include sand, cement, lime, aluminium and water. These raw materials are poured into a mould in a slurry form. They are then transferred to the pre-cure room. The small amount of alu- minium in the slurry reacts with the water and lime and forms hydrogen gas bubbles. The liberated gas forms extremely small bubbles within the mass, causing the mixture to expand within the mould to twice its original height. Once the material has reached the correct sufficient height and hardness in the pre-curing room, it is ready for cutting. It is now referred to as a cake. The amount of expansion is variable, and cannot be precisely controlled as it is dependent on environmental factors such as ambient temperature and humidity. The cakes are trimmed to size and cut both horizontally, and vertically into the required block size, using piano wires. The cakes now cut to block size are fed into autoclaves where they are steam cured. There are six autoclaves on the site. During the autoclaving process, further reactions take place with the formation of calcium silicate hydrates, which gives strength to the blocks. After autoclaving the blocks are separated without dismantling. Colour-cod- ed straps are then placed around the pack of blocks, depending on their strength; Super, Standard and Seven. The blocks are then wrapped for delivery to site. Cuttings from the blocks prior to blocks entering the autoclave, are recycled as “returns” and re-mixed in with the slurries. Cuttings from the blocks after the autoclave, are re-used in the nearby Mannok cement plant as minor additional constituents in the production of Portland cement. In doing so, they leave the system bound- ary of this LCA, having passed beyond the end-of-waste stage. The cuttings are now a raw material input in an external manufacturing process for another product, and have zero impact in relation to the LCA for the Mannok Aircrete blocks.
General comment on data set Data flows have been modeled as realistically as possible. Data quality assessment is based on the principle that the primary data used for processes occurring at the production site is selected in the first instance. Where this is not available, other reference data is selected from appropriate sources. Data collection period The dataset is representative for the production processes used in 2017 The process descriptions and quantities in this study are reproducible in accordance to the reference standards that have been used. The references of all sources, both primary and public sources and literature, have been doc- umented in the LCA report. In addition, to facilitate the reproducibility of this LCA, a full set of data records has been generated which can be accessed via the EcoChain tool. This data portfolio contains a summary of all the data used in this LCA, and correspondingly, in the Mannok Aircrete blocks EcoChain account.
Copyright Yes
Owner of data set
Quantitative reference
Reference flow(s)
Time representativeness
Data set valid until 2023
Time representativeness description "18.09.2018" - "18.08.2023"
Technological representativeness
Technology description including background system A1. Raw materials supply This module considers the extraction and processing of all raw materials and energy which occur upstream to the Mannok Aircrete blocks manufacturing process, as well as waste processing up to the end-of waste state. A2. Transport of raw materials to manufacturer This includes the transport distance of the raw materials to the manufacturing facility via road, boat and/or train. A3. Manufacturing This module covers the manufacturing of Mannok Aircrete blocks and includes all processes linked to production such as extrusion, mixing, packing and internal transportation. Use of electricity, fuels and auxiliary materials in fiber production is taken into account as well.

Indicators of life cycle

IndicatorDirectionUnit Raw material supply
A1
 Transport
A2
 Manufacturing
A3
Use of renewable primary energy (PERE)
Input
  • 0.724
  • 0.00175
  • 0.096
Use of renewable primary energy resources used as raw materials (PERM)
Input
  • 0
  • 0
  • 0
Total use of renewable primary energy resource (PERT)
Input
  • 0.724
  • 0.00175
  • 0.096
Use of non renewable primary energy (PENRE)
Input
  • 2.21
  • 0.144
  • 0.264
Use of non renewable primary energy resources used as raw materials (PENRM)
Input
  • 0
  • 0
  • 0
Total use of non renewable primary energy resource (PENRT)
Input
  • 2.21
  • 0.144
  • 0.264
Use of secondary material (SM)
Input
  • 0
  • 0
  • 0
Use of renewable secondary fuels (RSF)
Input
  • 0
  • 0
  • 0
Use of non renewable secondary fuels (NRSF)
Input
  • 0
  • 0
  • 0
Use of net fresh water (FW)
Input
  • 0.000388
  • 0.00000778
  • 0.0000808
Hazardous waste disposed (HWD)
Output
  • 0.00000608
  • 9.96E-7
  • 9.41E-7
Non hazardous waste dispose (NHWD)
Output
  • 0.229
  • 0.00649
  • 0.00138
Radioactive waste disposed (RWD)
Output
  • 0.00000552
  • 9.15E-7
  • 8.87E-7
Components for re-use (CRU)
Output
  • 0
  • 0
  • 0
Materials for recycling (MFR)
Output
  • 0
  • 0
  • 0
Materials for energy recovery (MER)
Output
  • 0
  • 0
  • 0
Exported electrical energy (EEE)
Output
  • 0
  • 0
  • 0
Exported thermal energy (EET)
Output
  • 0
  • 0
  • 0

IndicatorUnit Raw material supply
A1
 Transport
A2
 Manufacturing
A3
  • 1.99
  • 0.142
  • 0.311
  • 0.000984
  • 0.0000649
  • 7.73E-7
  • 0.000987
  • 0.0000223
  • 0.000117
  • 0.00011
  • 0.00000283
  • 0.00000887
  • 0.41
  • 0.00892
  • 0.0239
  • 2.19E-8
  • 1.62E-9
  • 6.41E-10
  • 0.0000682
  • 0.00000139
  • 0.00000526