Saltech Design Labs manufactures building materials from recovered waste, using raw materials comprising plastic, aggregate and filler. These materials are moulded into Paver Blocks, Paver Tiles, Floor Tiles, Road Slabs, Grass Paver and Solar Tiles. Saltech partnered with Monk Spaces to conduct a Life Cycle Assessment (LCA), publish an Environmental Product Declaration (EPD), and develop an Estimator sheet. The LCA conducted adhered to internationally acceptable standards like ISO 14040: 2006, ISO 14044:2006 and EN 15804+A2

The assessment involves the following steps:

1. PCR Identification: The first stage initiates with the identification of the PCR 2019:14 – Construction Products for Saltech Products. The PCR follows general program instructions (GPI) of the International EPD System. It mandates the declaration of impact indicators like global warming potential (GWP), acidification potential (AP) and many others. The PCR also declares the mandatory modules to be included for the production (A1-A3), end-of-life (C1-C4) and benefits (D) stages. These modules guide in deciding what data to collect across various product lifecycle stages.
2. Data Collection: Based on PCR requirements, a detailed data collection sheet, including pilot and commercial phases, was developed for the manufacturer’s convenience. The data includes details on plastic waste procurement, other raw materials, electricity and water consumption, manufacturing and packaging.
3. Conducting LCA: Once the details are filled out, the environmental impacts for pilot and commercial phase products are evaluated. The results are quantified using the OneClick LCA and Ecoinvent database across core categories, such as natural resources, wastes, and output flows. The quantified results were then integrated into LCA reports which helped to analyse the key performance indicators for both phases. The significant contributors to environmental impacts across the phases were identified and recommendations were given regarding decarbonisation strategies for the commercial phase.
4. Estimator: An Excel estimator sheet was developed to analyse the environmental impacts of new product compositions using the same raw materials. This sheet includes the quantities of raw materials like plastic waste, aggregate, filler, compatibilizer, and paint and their transportation distance. It also includes manufacturing details such as water consumption, electricity consumption, material wastage, and packaging.

4. EPD Development: Following the analysis, the next step involves developing EPDs. Once the LCA results were finalised, two EPDs were developed based on the average representative of Saltech Products. One for Saltech Pavement Products manufactured with 21-40% plastic, and another for Saltech Slabbing Products with 41-60% plastic. The LCA results and other information are compiled for the EPDs. The EPDs compiled follow the General Programme Instructions from the International EPD System.
5. EPD Verification: The EPDs were verified by an accredited third-party verifier associated with the International EPD System. Modifications were made wherever required in response to the verifier’s feedback. Effective coordination with the verifier ensured comprehensive responses to all queries and timely provision of clarifications.
6. EPD Publication: After approval from the verifier, the EPDs are uploaded onto the EPD portal of the International EPD system. This contains product information, result templates, LCA report and verification statement. After approval from the EPD secretariat, the EPDs were published.

The LCA conducted for Saltech helped them understand the environmental impacts of both their existing and prospective products.