Selling Precast in a Green World Sustainability Council Marketing/Sustainability Committee Jim Lewis, RA, LEED AP

Selling Precast in a Green World

Sustainability Council

Marketing/Sustainability Committee

Jim Lewis, RA, LEED AP

Program OverviewProgram Overview

Selling Precast in a Green World

The audience for this program are sales and marketing professionals engaged in the direct sales of precast concrete products.

This program is not meant to replace experience in selling precast but to further educate and add to the tools to make a convincing argument for the use of precast concrete in sustainable green design.

Program OverviewProgram Overview

Selling Precast in a Green World The green building market and GreenWashing

Green certification, codes and standards

Selling to sustainable minded architects

How precast contributes to sustainable design

Competitive products

Sustainable plant practices

PCI resources

“Meeting the needs of the present, without compromising the needs of future generations to meet their own needs.”

What does Sustainability Mean?What does Sustainability Mean?

GREEN is changing the

way products are sold,

marketed, and developed.

Truth aside, everyone claims to be green Increasing number of “green” building

materials/products Product features and benefits are

manipulated to reflect green attributes

The Red Light on Green WashingThe Red Light on Green Washing

The Red Light on Green WashingThe Red Light on Green Washing

What NOT to say: “LEEDS”

“Precast is green”

“Precast can guarantee LEED points”

Never make unsubstantiated claims

Competing systems “are not sustainable or green”

Building a sustainable future

Sustainable Building Market Sustainable Building Market

Sustainable Building MarketSustainable Building Market

Green Building Market

0

2040

6080

100

120140

160

2005

2007

2009

2011

2015

Green building accounted for about 10 billion dollars in 2005In 2009, despite an overall construction downturn of 25%, green building grew to $60It is expected to reach over $70 billion in 2010And, green building is expected to reach upwards of $135 billion in 2015It is a steadily growing percentage especially fast growing in government and school markets.

Designers specify hundreds of systems/products per project

Limited knowledge of products/systems Time constraints Illusion of an organized up to date library Path of least resistance; they come back to

the products/systems they know

Selling to Sustainable Minded ArchitectsSelling to Sustainable Minded Architects

Sustainable construction involves an integrated design team.

Holistic approach to building design Adjust and shift budgets to meet goals Make trade-offs to improve overall design Get on the team early in the process Collaborate and solve problems vs.

pitching products.



Remember – Most Designers know more

about green building practices…

but you know more about precast systems.

ArchitectsThinkVisually


Case in Point.. Case in Point..


Use Case Studies:

Idea generators Demonstrate how

precast contributed Develop your own or

use PCI case studies Include quotes and data Create envy of their

brethren

Case Studies Demonstrate: Materials & Resources Case Studies Demonstrate: Materials & Resources

University of North FL Social SciencesBuilding

Styrofoam XPS insulation with 40% postindustrial recycled content

Recycled steel, welded wire, connections

Gray cement w/silica fume, fly ash for interior. Gray cement used only on

interior to not effect final color of exposed concrete.

Certification, Codes and StandardsCertification, Codes and Standards

“How do you know a building is sustainable?”


USGBC LEED Rating System

Introduced in 2000

2000: 380 projects were registered

2009:10,000 projects

2010: LEED cited in 71% of projects valued over $50M

LEED CATEGORY CREDIT OR PREREQUISITE

Credit Title LEED NC v2.2 LEED 2009

Sustainable Sites

SS Credit 5.1 Site Development, Protect or Restore Habitat 1 1

SS Credit 7.1 Heat Island Effect, Non-Roof 1 1

SS Sub-Total 2 2

Energy & Atmosphere

EA Prereq 2 Minimum Energy Performance Required Required

EA Credit 1 Optimize Energy Performance 1-10 1-19

EA Subtotal 10 19

Materials & Resources

MR Credit 2.1 Construction Waste Management, Divert 50% from Disposal 1 1

MR Credit 2.2 Construction Waste Management, Divert 75% from Disposal 1 1

MR Credit 4.1 Recycled Content, 10% (post-consumer + pre-consumer) 1 1

MR Credit 4.2 Recycled Content, 10% (post-consumer + pre-consumer) 1 1

MR Credit 5.1 Regional Materials, 10% Extracted, Processed & Manufactured Region 1 1

MR Credit 5.2 Regional Materials, 20% Extracted, Processed & Manufactured Region 1 1

MR Subtotal 6 6

Indoor Environmental Quality

EQ Credit 3.1 Construction Indoor Air Quality Management Plan: During Construction 1 1

EQ Subtotal 1 1

Innovation & Design Process

ID Credit 1.1 Innovation in Design: Provide Specific Title 1† 1

ID Credit 1.2 Innovation in Design: Provide Specific Title 1† 1†



ID Credit 1.5 Innovation in Design: Provide Specific Title -- 1†

ID Credit 2 LEED® Accredited Professional 1 1

LEED NCv2.2: LEED Certified = 26 points ID Subtotal 1 2LEED 2009: LEED Certified = 40 points Project Totals 20 30

†Up to four additiona points can be earned, must be submitted and approved (not included in total).

POINTS AVAILABLE

LEED v2.2 vs LEED 2009

What’s wrong with LEED?

High costs of registration/certification Complexity and bureaucratic requirements for

certification Lack of rigor in the rating system Lack of lifecycle analysis after certification Potential risk/litigation when not achieved “Self Administered” resulting in subjectiveness



“Excuse me guys, I think you’ll get more bang for the buck if we use LEED concepts….and forego the project registration.” Lisa Stacholy, AIA

$75k premium to construct 17,000 SF classroom building with LEED Certification

Board: build sustainably, save cost of enhanced commissioning, energy modeling & registration

Install ground source heat pumps with savings Evidence of trend – sustainable but not LEED Not to say LEED criteria is not followed – it

provides an excellent guideline for SUSTAINABLE DESIGN


Green Globes Certification


Energy Star for Buildings

Performance based. Measures energy management

strategies. Cost less to operate and

improve the quality of our environment.

Yearly renewal.


International Green Construction Code

Performance based,

scientific approach Developed in collaboration with AIA, ASTM,

ASHRAE, ANSI Promotes energy efficient performance,

durability, maintenance, life cycle 2012 Introduction

How does the new IgCC benefit precast?

More emphasis on energy efficiency Looks at life-cycle cost reduction/durability Emphasis on 60-year building life Potential for more “whole building analyses” Sound transmission requirements.



Mandatory if adopted Performance based,

focused on energy and resource efficiency

Enforced under existing code offices in a jurisdiction

Voluntary Focuses on renewable,

sustainable resources Prescriptive based Compliance oriented

around requirements and templates

ASHRAE 189:

High performance green buildings Framework for local code modifications Water and energy efficiency Indoor air quality Materials and resource use Construction practice, site impact Alternate path to IgCC compliance


ASHRAE 90.1 2010

Recognizes thermal mass of concrete

Continuous insulation required


Absorbs outside and inside heat and slowly releases.

Delays onset of peak heating or cooling loads. May reduce peak demand

and energy consumption. Downsized HVAC systems. Reduces indoor temperature

fluctuation, improve occupant comfort.

Thermal mass effect varies by climate.

Thermal Mass EffectThermal Mass Effect

Quad City Botanical CenterRock Island, Illinois

Precast Contributions to Sustainable Design


Centralia High School, Centralia, IllinoisArchitect: FGM Architects



Thermographic image shows how

water has penetrated brick joints,

affecting integrity and effectiveness

of insulation.

• Temp at ceiling is 71.0 °F

• Temp at desk height is 64.3 °F

• Temp at children’s feet is 60.2 °F

Precast Contributions to Sustainable DesignPrecast Contributions to Sustainable Design

Markin Family Recreation CenterPeoria, IL


Sustainable site: Ready to erect No jobsite waste or pollution Minimal site disturbance Ease of erection in confined spaces Improve safety on site No formwork, curing time, weather delays Speed benefits construction schedules


Materials:

Manufactured locally Uses abundantly available natural resources Recycled materials Strategies to reduce weight Load carrying capabilities optimize cross sections


Indoor air quality:

Does not off-gas Low/no VOCs Not damaged by moisture No mold growth No need to seal or paint Polished concrete floors require no carpeting No wall finishing, no drywall dust, paint


Material Resources:

Little waste Waste is recycled Reusable formwork Long service life, low maintenance Panels can be dismantled reused, recycled Recycled concrete can be used as fill, road

base, shore protection


Brick and Stone Masonry

Promotes durability and reuse Historic brick is often restored Modular units eliminate waste Concrete block provides fire

wall separation Provides structure and interior walls Demolition and construction waste can be

crushed, used for fill, landscape

Competitive SystemsCompetitive Systems

Brick and Stone Masonry Replace cement with fly ash and slag Uses recycled aggregates Available locally Exposed walls eliminates finishes

Site impact Speed



Cast-in-Place Concrete

Same sustainable attributes

of concrete – but a site disaster.

Delivery trucks Formwork, scaffolding Material waste Weather dependent Time issues QC at the jobsite


Green Building with SteelSteel is the mostrecycled material in the world.

High strength steel for

a lighter structure

Steel is available locally

Steel buildings can be

designed for deconstruction

National Works Yard, Vancouver, LEED Gold


Steel and recycled content

Oxygen Furnace process uses 25%-35% recycled steel.

Electric Arc Furnace process uses 90%-100% recycled steel.

Post-consumer and post-industrial recycled contents provides 15-20% LEED™ value for BOF and 75-90% recycled content for EAF.

Most North American structural steel are produced using EAF with 90% recycle content.

http://www.google.com/imgres?imgurl=http://www.csiro.au/images/mediaReleases/furnace_med.jpg&imgrefurl=http://www.csiro.au/files/mediarelease/mr2001/SteelMillWaste.htm&h=283&w=280&sz=24&tbnid=9E_QMad9Idyj3M:&tbnh=226&tbnw=223&prev=/images?q=steel+mill+photos&zoom=1&q=steel+mill+photos&usg=___JhwfoJoilISqsU7umqZT_LmMzY=&sa=X&ei=ntAlTfnFI4T6lwezh6SGAg&ved=0CCUQ9QEwAA

Steel industry is improving its sustainability

Improved recycling and reuse since the turn of the century

Reduced energy consumption & CO2 emissions by 20% since 1990

Great efforts are being made to create and understand the sustainable potential of steel


PCI Sustainable Plant ProgramPCI Sustainable Plant Program

What is our industry doing to be more sustainable?

PCI Sustainable Plant Program

Provides guidance Measure baseline Improve performance Share best practices

Sustainable Plant PracticesSustainable Plant Practices

Energy efficiency: Develop formal energy plan; benchmark, track

progress Reduce therm per yd/concrete Reduce (gas/propane) diesel fuel oil per

yd/concrete


Energy efficiency: Investigate and install high efficiency lighting

systems -T-8s, T-12s and T-6s fluorescents or LED fixtures

Clean light covers, lenses and bulbs to increase output quality

Regularly check steam lines for leaks Insulate forms Use curing blankets

instead of electric or steam


Energy efficiency: Use lighting motion sensor/daylight sensors Daylight or skylights on roofs and vertical

walls for natural daylight Train your teams to be more energy conscious


Energy efficiency: For motors and elec. panels-use of power

conditioning systems and Transient Voltage Surge Suppression systems (TVSS)

Optimize power factors with kvar technology www.coloradokvar.com Implement procedures for efficient start-up and

shut down of equipment to avoid unnecessary run times

http://www.coloradokvar.com/

Material sourcing:

Choose suppliers with

environmental practices in place Purchase recycle or recycled content Source local materials with lower transportation cost Look for green certified materials. Forest Stewardship

Council, Green Seal, UL Environment


Waste management: Separate and recycle steel, rebar,

mesh, strand, insulation, oil, paper,

packaging Implement cardboard recycling Recycle all office paper waste Recycle computers, donate to local charities Donate or sell used equipment


Waste management:

Crush product rejects,

sell as road base Formwork disposal; use chipper

for mulch, fuel, compaction Use reusable forms Install water reclamation and reuse system Reclaim aggregate from washout Collect rain water



Transportation efficiencies:

Use electric carts around plant Put truck idling policy in place Limit truck speed Decrease handling/internal transportation Organize to minimize equipment usage Retire old trucks & equipment Investigate rail, barge for delivery

Transportation efficiencies:

Avoid delivery routes with heavy traffic Plan load weights vs. routes options Minimize tractor time on site Plan delivery and erection

sequence to minimize time,

energy, site impact, cranes



Optimize mix:

Use SCMs to replace

Portland cement

Use recycled aggregate Low VOC release agents,

retarders, cleaners Use FSC certified wood, no formaldehyde


Metromont Sustainable Plant Practices

Sells waste/reject concrete for road base Reclaim aggregates from washout Separate rock and sand for restocking Water processing and reuse Waste product crushed for grading material Insulate forms Sizing compressors to conserve power Regularly inspect and fix air leaks


Mid-States Concrete IndustriesSustainable Plant Practices

Reduced compressed air pressure 120psi to 100 psi – 10% reduction in energy

Raise temp. on compressed air dryer from 34 to 45 degrees – 10% energy reduction

Changed half metal halide lights with fluorescent lamps – 30% less energy

Using 20% recycled water for concrete washing and cutting

Selling waste strand and rebar Using 95% efficient heater for batch water Recycling paper, cardboard, aluminum, plastic

Data you should collect:

Document raw materials origin. Document pre-consumer and post-industrial

recycled content of each. Possible recycled content by material:

- Rebar 80-90% - Forming materials

- Insulation 90-100% - Formliners 85-95%


PCI ResourcesPCI Resources

PCI Resources:

PCI Sustainable Plants Program Webinars summer 2011 PCI member consulting companies PCI web site with Case Studies Designer’s Notebooks Got Proof CD/Thumb Drive

Questions?


Melrose 5

Precast 85% regionally produced,10% recycled content.

Load-bearing exterior and interior walls for long clear spans and to facilitate remodeling or building reuse.

Hollow-core floor/wall units cast in reusable steel formwork, eliminated 98% of wood needed for concrete formwork on site.


North Central College 40% recycled content. Slag substituted for virgin

limestone. Fly ash replaced 30% cement. Slag lowered density

concrete (125 pcf vs.150 pcf). Reduced weight allowed more

panels per truck. Lighter weight results in

savings in foundation construction.

Walls have 3- to 4-hour fire rating and R19 energy rating.

Case Studies Demonstrate: Materials & ResourcesCase Studies Demonstrate: Materials & Resources

Missoula Credit Union Precast concrete was

made from materials harvested, extracted, and produced within 500 miles of site.

Concrete used fly ash and recycled glass, no cement!

Two citywide glass drives provided glass for the concrete.

Recycled glass used for pipe bedding, fine grading, landscaping, tiles, counters.

Case Studies Demonstrate: Innovation in DesignCase Studies Demonstrate: Innovation in Design

University of FloridaCancer and GeneticsResearch Center

Saved over 1150 tons of mined clay

Saved over 12,000 gallons of diesel fuel

Saved over $69,000 in material costs

Innovation in Design Innovation in Design

Cancer Genetics Research Center – University of Florida, Gainesville, FL

Thin Brick (actual) Full Bed Depth Brick (estimated)Raw material mined (clay) 288 tons 1,440 tonsShipping raw materials to brick plant 13 loads, 39 gallons fuel $109 64 loads, 192 gallons fuel $537Firing costs 710 mmbtu $8,520 3,500 mmbtu $42,000Shipping bricks to precast plant 12 loads one way = 1,470 gallons fuel $4,116 100 loads one way = 12,250 gallons fuel $34,300

SavingsRaw Materials 1,152 tonsDiesel Fuel 12,648 gallonsNatural Gas 2,790 mmbtuCosts $68,894

The material saved alone would produce an additional 400,000 sf = 2.7 million pieces of thin brick.

Comparison calculation: thin brick vs. full bed depth brick1.) 100,000 sf of thin brick equates to 675,000 pieces of full bed depth brick2.) Modular size bricks 3-5/8” x 2-1/4” x 7-5/8”; Thin brick, 5/8” x 2-1/4” x 7-5/8”3.) Shipping distance for raw materials: 12 miles and trucks return to mine empty (24-mile round trip)4.) Shipping distance for finished product: 980 miles5.) Modular-size brick creates job site and construction waste vs. thin brick with Zero construction waste.6.) Fuel mileage for all trucking: 8.0 miles per gallon.7.) Diesel fuel cost: $2.80 per gallon8.) 10% loss on ignition (organic materials burned during kiln firing)9.) All trucking capacities: 45,000 lbs.10.) Natural gas cost delivered to plant : $12/ mmbtu

Case Studies Demonstrate: Energy & Atmosphere Case Studies Demonstrate: Energy & Atmosphere

University of North FL Social Sciences Building

Sandwich wall system with

R-value of 24. Utilizes 20% less energy

than baseline ASHRAE 90.1 30% more efficient than

required by code. $28,210 in annual energy

savings.

Documents

Selling Precast in a Green World Sustainability Council Marketing/Sustainability Committee Jim Lewis, RA, LEED AP