GCS12A

Understanding Recycled Content Surfacing Materials:

Its value under LEED® and beyond

Credit for this course is 1 AIA/CES HSW/SD CE Hour

1 GBCI CE Hour For LEED Professionals

0.1 CEU for Interior Designers

© GreenCE, Inc. 2010

Barb Lyons Cosentino North America

13124 trinity drive stafford, tx 77477

281-380-9778 barbl@cosentinousa.com

Please note: you will need to complete

the conclusion quiz online at

greence.com to receive credit

An American Institute of Architects (AIA)

Continuing Education Program

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• GreenCE, Inc. is a registered provider with The American Institute of Architects

Continuing Education System. Credit earned upon completion of this program will be

reported to CES Records for AIA members. Certificates of Completion are available

for all course participants upon completion of the course conclusion quiz with +80%.

• This program is registered with the AIA/CES for continuing professional education. As

such, it does not include content that may be deemed or construed to be an approval

or endorsement by the AIA or GreenCE, Inc. of any material of construction or any

method or manner of handling, using, distributing, or dealing in any material or

product.

An American Institute of Architects (AIA)

Continuing Education Program

• Course Format: This is a structured, web-based course with a final exam.

• Course Credit: 1 AIA Health Safety & Welfare (HSW), Sustainable Design

(SD) CE Hour

• Completion Certificate: A copy is sent to you by email or you can print one

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Please note: you will need to complete the conclusion quiz

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GreenCE, Inc.

1

Understanding Recycled Content Surfacing Material:

Its value under LEED

GBCI Course ID: 90003939

GBCI CE Course

IDCEC

• This CEU is registered with the Interior Design Continuing Education Council (IDCEC) for

continuing education credits. This credit will be accepted by the American Society of Interior

Designers (ASID), International Interior Designers Association (IIDA) and Interior Designers of

Canada (IDC).

• The content included is not deemed or construed to be an approval or endorsement by IDCEC

of any material or construction or any method or manner of handling, using, distributing or

dealing in any material or product.

• Questions related to specific materials, methods and services should be directed to the

instructor or provider.

• This program is registered for 0.1 CEU (continuing education credit).

• IDCEC Course Details:

– Author: Dennis Rickman

– Designation: Health & Safety / Welfare

– Subject: 5.3

– Classification: Basic

– IDCEC Course number: 5975

**Participants must submit their completed NCIDQ CE Registry Participant Form to NCIDQ directly.**

Online at MyNCIDQ – CLICK HERE

By completing this course, the design professional will be able to:

• Define the difference between “green” buildings and “green”

products

• List the benefits of recycling

• Describe the basic content of recycled surfacing products

• Compare and contrast traditional surfacing materials to recycled

content surfacing products

• Describe how the manufacturing process of recycled content

surfacing materials can be environmentally responsible.

Course Learning Objectives

Course Learning Objectives

• Explain the advantages of resin-based recycled content surfacing

to other products that are typically specified

• Explain how recycled products can contribute (directly and

indirectly) to obtaining points under the LEED program

• Describe what Cradle-to-Cradle and GREENGUARD certifications

are and why they are important

• Explain the importance of specifying and using recycled content

surfacing products as related to environmental issues

• Explain the importance of going beyond “green”

Building Green

LEED certified buildings are designed to:

• Efficiently use energy, water, and other resources

• Protect occupants health and enhance the comfort and well-being

of the occupants

• Reduce waste, pollution and environmental degradation

• Utilize sustainable design options

• Provide these qualities through the entire building’s life-cycle

* Remember: LEED ACCREDITS individuals and CERTIFIES buildings

(certified, silver, gold, platinum) but does neither for materials!

There are NO green materials under LEED–Just environmentally

conscientious materials/products that can contribute to a project obtaining

LEED points.

Green Building Materials

Building materials typically considered to be “green” include:

• Rapidly renewable plant materials like bamboo and straw

• Lumber and wood based materials certified in accordance with FSC

standards

• Recycled stone

• Recycled steel

• Other products that are non-toxic, reusable, renewable, and/or

recyclable (i.e. glass, ceramics, linoleum, sheep wool)

Benefits of Product Recycling

Benefits of Product Recycling

Environmental Benefits

• Reduces the materials in landfills

• Facts – Over 300,000,000 tons of waste

placed in landfills annually, nearly

one ton per person, and it is

growing every year

– Plastic cups take over 250 years

to decompose

– Glass essentially NEVER does

– Currently only 28% of glass is

recycled

Benefits of Product Recycling

Environmental Benefits

• Reduces the amount of air pollutants

• Facts:

– For every ton of glass that is

recycled, 750 lbs. of carbon

pollution can be eliminated

– Production of glass is very energy

intensive

– The carbon emissions combine with

oxygen to form CO & CO2 thus the

enormous weight

Benefits of Product Recycling

Economic Benefits

• Saves energy consumption

• Facts

– Recycling of a single glass

bottle daily saves enough

energy in a year to power:

• A compact fluorescent bulb for 3.5 months

• A computer for over 5 days

• A television for 3.3 days

– Recycled surfacing products from a single manufacturer

currently uses over 60 million bottles annually

Products Available

Recycled Content • Glass

• Paper

• Ceramics/Porcelain

• Ash

• Metals

• Stone

• Combination

Products Available

Matrix/Binders

• Cement

• Resins

– Polyester

– Vegetable based

In-Depth Analysis

Ash

Granite

Glass/Ceramic

Mirror

Pigment

Micronized glass

Vegetable-based resin

In-Depth Analysis

• All of these elements are recycled except for the resin, which

constitutes less than 7% by weight and a minuscule amount of

pigment.

• Contribution towards a LEED credit is based not on the percentage

that the glass is recycled (ex: contains 100% recycled glass) but

rather on the percentage of recycled glass in the product’s total

content by weight.

• So, for a 100lb surface, if 75% of the total content is recycled, the

product contains 75lbs of recycled content.

• This can be made up of multiple recycled products

Recycled Content

Micronized Glass

Post-Consumer Micronized Glass • Post-Consumer glass becomes

micronized and incorporated into

the slab

• Micronized glass is a recent

innovation

• The use of micronized glass

makes its possible to have a

high percentage of recycled

glass by weight

Crystallized Ashes

Post-Industrial Crystallized Ash • Derived from the ashes produced during the

burning of charcoal in industrial furnaces

• These furnaces release a ceramic residue that

comes into contact with the charcoal ashes

• When the mixture of ashes and ceramic residue

come into contact with water, they turn into solid

rocks

• These rocks are then pulverized and used as a

binder/filler for the matrix

Note: Ash used here is known as bottom ash and should

not be confused with fly ash, which is used in concrete

Vegetable-Based Resin

Environmentally Friendly Resins • Resins are used to bind the elements

• Resins make the end product virtually non-porous, thereby

eliminating sealing while providing a mold/mildew free surface that

is also highly stain resistant

• Vegetable-based resins

are a lot more

environmentally friendly

than pure petroleum or

polyester resins which are

commonly used

Recycled Materials

Post-Consumer and Post-Industrial LEED makes a distinction between

Post-Industrial and Post-Consumer recycled materials. Glass is no

exception.

Recycled Materials

• Although the use of both of these are environmentally

beneficial decisions, under LEED the use of post-

consumer waste is twice as valuable.

• The primary reason is that PI glass has not gone through

the natural life cycle and, secondarily, it is generally used

to produce more glass products, which requires melting

and a higher energy consumption than crushing the

material for recycling.

• Crushing conserves the embodied energy while

expending very little.

Recycled Porcelain and Ceramics

Post-Consumer and Post-Industrial

• From bathrooms, dishes, cups, shower pans and defective

porcelain tiles

• There is no other use for this material; it cannot be incorporated

into any other industrial product

• The reasons for recycling of these materials are very similar in

nature to that of glass, however they may actually be of increased

value because of the limited programs for recycling cumbersome

elements and therefore, a much larger % is found in landfills.

Note: Obtaining Water Efficiency LEED points in a renovation may contribute towards the increased waste of porcelain and ceramics.

Recycled Porcelain and Ceramics

• If we replace all of the existing toilets with low-flow

models, what happens to the old ones?

• Every year, tons of these materials end up in landfills

• There are increasing amounts of urinals and toilets being

discarded as we convert to low flow or dry flush systems

Recycled Mirror

Post-Consumer and Post-Industrial • This product has no other lifecycle

• Every year, tons of mirror fills our landfills

It is much more important to use these products due to the fact that

converting mirror waste is even more energy intensive than that of glass

because of the separation of the reflective materials (chromium, nickel,

and silver)

Other Raw Materials

Quarry Waste Quartz: the second most abundant mineral on earth, and therefore

nearly sustainable. Use of quarry waste not only helps by using a larger

percentage of a natural mineral/element, but it also assists in the

reclamation/reforestation of quarries

Other Raw Materials

Pigments Although much of the coloration

can be contributed by the

various elements (glass,

ceramics, ash) there are natural

and man-made pigments used

in minute quantities.

Manufacturing Process

• The BRETONSTONE® process known as "Vibrocompression under

Vacuum," makes it possible to work a dry mixture composed of

glass/ceramics, stone aggregates, and a vegetable-based resin

binder into a usable compound product.

Manufacturing Process

This particular process is used to manufacture

• Slabs

– 1.2cm & 2cm thickness

– 63” x 128”

– Countertops

– Walls

• Tiles

– 1.2cm

– Standard and Custom sizes

– Floors

– Walls

• The slab size is extremely large and can

effectively reduce the percentage of waste

normally associated with smaller slabs

Manufacturing Process

This is how the RAW slab would look:

Compaction under vacuum:

Greatly reduces porosity and strengthens the physical

bond

Manufacturing Process

Manufacturing Process

• This machine is the true essence of the process.

• The raw slab is simultaneously subjected to near violent

vibration and nearly 3 million pounds of pressure per

square foot. This force effectively duplicates what nature

produces in the formation of granite.

• After this process, the final density is approximately 94%

of that of granite.

Manufacturing Process

The compressed slabs are then sent to a highly efficient/low

temperature vertical oven where the internal temperature of

the slab is raised to approximately 145 F. Only a minimal

amount of energy is required to cure the resins through this

process.

Manufacturing Process

• The next phase of manufacturing

is essentially the same as that

used in the processing of natural

stone slabs or tiles.

• The slab is now calibrated, honed

and finally polished using a

series of ceramic heads

embedded with industrial

diamonds

• This is a close-up view of the

ceramic (diamond embedded)

polishing heads and the “foam”

that is produced during the

process

Manufacturing Process

• The polishing process produces extremely fine airborne particles, which contributes towards poor indoor air quality and is extremely harmful to workers.

• In order to prevent these problems, this entire operation is conducted with the use of 94% recycled water.

• The remaining 6% is evaporated and the slurry remnant can be reincorporated into other products.

• The following photo on the right depicts what would normally be discharged into the natural water system by less environmentally conscience plants/facilities and where strict pollution control is not enforced or existing.

Manufacturing Process

Manufacturing Process

Comparing Surface Products

Until the advent of recently engineered products, the A/D community

really had only two general categories of materials that would be

specified for the large majority of surfaces:

Natural Stone Surfaces

All of these materials tend to have inherent structural problems and are

prone to staining and require initial and periodic sealing, which are

typically chemically-based and due to high VOC content, contribute

towards poor indoor air quality.

Additionally, it should be noted that the finished natural stone products

represent less than 25% of the original quarried material. This is not an

efficient use of natural resources.

Comparing Surface Products

Acrylic Solid Surfacing

These products are scientifically known as Polymethyl Methacrylate

(PMMA), an acrylic based thermoplastic that is produced from a

chemical reaction between acetone and hydrogen cyanide resulting in

acetone cyanohydrin. This is then heated with methanol and sulfuric

acid and becomes a monomer called methyl methacrylate monomer or

"MMA." It then becomes a polymer via a free radical process using

peroxides.

Essentially, solid surfacing materials are plastic produced from a

variety of harmful chemicals.

Comparing Surface Products

• Yes, despite it’s popularity, it is truly an environmental disaster;

from the extraction of the raw materials through the manufacturing

process, to it’s limited life cycle and eventual non-biodegradable

presence in our landfills.

• More over, this plastic product is

based on a non-renewable

resource, oil.

Comparing Surface Products

Concrete or Concrete Composite

Many products on the market today have recycled glass in them.

Unfortunately, when you consider the Embodied Energy of the

concrete with a nominal amount of recycled glass, is it worth it?

Actually, concrete itself has an inherently low embodied energy,

but it must be quarried, produced and transported. Additionally, it

is the most widely-used material in existence, thus producing a

high net effect of emissions. So widespread is the use of

concrete, that nearly 2 tons is produced for every person on the

planet.

Every ton of cement manufactured for use in concrete emits a ton

of greenhouse gas carbon dioxide (CO2) into the atmosphere.

Comparing Surface Products

Comparing Surface Products

• The following chart is an accurate comparison of the typical products

that are specified for a commercial project.

• The TOP row represents the basic/generic materials. The products

are listed from right to left in ascending order of DURABILITY

• The far left column represents the most important

characteristics/attributes that a designer/architect/owner would like to

see in the specified materials

• It is obvious from the chart that each of the materials have some of

these traits, but only recycled surfacing products have ALL of them.

Material/Attribute

Recycled Surface

made w/ vegetable resin Granite Solid Surface Ceramic Tile Laminate

Stain Resistant Yes No Yes Yes Yes

Burn Resistant Yes Yes No Yes No

Scratch Resistant Yes Yes No No No

Large Color Palette Yes Yes Yes Yes Yes

Mold/Mildew Resistant Yes No Yes Yes Yes

5 Year Warranty Yes No Yes No No

Sustainable Yes No No No No

Comparing Surface Products

LEED ® - USGBC

• USGBC is the governing body

• LEED is the rating system

• REMEMBER it is LEED, NOT LEEDS (there is no “S”)

• Buildings are Certified

• People are Accredited

• Products are not recognized as

accredited or certified by USGBC

or LEED

• The Leadership in Energy and Environmental Design

(LEED) Green Building Rating System, developed by the

U.S. Green Building Council (USGBC), provides a suite of

standards for environmentally sustainable construction

• Since its inception in 1998, LEED has grown to

encompass more than 14,000 projects in 50 US States

and 30 countries covering over a billion square feet of

development area

LEED

The hallmark of LEED is that it is an open and transparent

process where the technical criteria proposed by the LEED

committees are publicly reviewed for approval by more than

18,000 membership organizations that currently constitute

the USGBC.

LEED

LEED Green Building Market

• This is a graphic representation of how the “green”

movement has and will continue to grow.

• Since 2005, when the green building movement gained

momentum and began being charted until nearly 2008,

the growth was minimal. However, each subsequent year

it has increased by nearly 50% and projections for the

future are even higher

LEED Green Building Market

Direct LEED Contributions

• Let’s now look at how recycled content surfacing

materials can DIRECTLY CONTRIBUTE towards

obtaining LEED points for building certification

• Although the formula is a little complicated, the

application is fairly simple.

• FIRST we must assume that all prerequisites are met.

Direct LEED Contributions

The $ value of the material for the entire building must be

ascertained. This can either be done by using the LEED

simplified method (assumes that the total material cost is

50% of all building costs) OR the exact cost is calculated by

adding all the material invoices (this method usually

produces a smaller figure but is much more involved). It

may be beneficial to take the more difficult approach

because the less the overall material costs are, the less the

GOAL for recycled content is.

Direct LEED Contributions

Once the dollar goal is established, then the calculation for

the value of the recycled material content is made. The

dollar value of each material that is used is derived from

multiplying the cost of the material by the % of recycled

content. If the recycled content is ALL Post Consumer, you

will get 100% dollar value credit toward the goal. If the

recycled content is 100% Post-Industrial, you will receive

only half (50%) of the $ value of that material. If the product

contains both PC & PI, you will be awarded a $ value pro-

rata.

Direct LEED Contributions

LEED v3 2009 for New Construction and Major

Renovations

• MR Credit 4.1

Recycled Content: 10%

(post-consumer + 1/2 pre-consumer)

1 Point

• MR Credit 4.2

Recycled Content: 20%

(post-consumer + 1/2 pre-consumer)

1 Point

• ID Credit 1 (Path 2)

Exemplary performance 30% recycled content

1 Point

Indirect LEED Contributions

LEED v3 2009 for New Construction and Major Renovations

• MR Credit 7: Certified Wood = 1 Point

The inherent tensile and flexural strength of certain recycled

content surfacing products effectively eliminates the required

usage of composite wood and agrifiber products (particle board,

MDF and plywood) that is necessary as an underlayment which is

required when using other surfacing products. Necessary

incorporation of these products will detract from obtaining a project

goal for obtaining this FSC-certified wood credit

Indirect LEED Contributions

LEED 2009 for New Construction and Major Renovations

• EQ Credit 4.1

Emitting Materials: Adhesive and Sealants

1 Point

– Materials recommended for installation are readily available

and their VOC content is less than the current VOC content

limits of South Coast Air Quality Management District

Regulation 8, Rule 51

– Recycled content surfacing products made with resins

never require sealing, thereby eliminating the need for

products that generally contain VOCs, are odorous, irritating,

and/or harmful to the comfort and well-being of the installers

and occupants

Indirect LEED Contributions

LEED 2009 for New Construction and Major Renovations

• IEQ Credit 4.4

Low Emitting Materials: Composite Wood and Agrifiber Products

1 Point

We have established that the underlayments used are NOT from

FSC wood. They are made from, or at least bonded with, urea-

formaldehyde resins, which produces air contaminants and is

potentially harmful. Not having to use these materials will not only

enhance the air quality and the environment, but will contribute

towards attaining this point.

• Cradle to Cradle certifies that products are designed to maximize

their life and reduce the waste once it reaches the end of its cycle

• It also assures that products are manufactured in a respectful

manner, so as to not squander the resources employed during the

manufacturing process

• It audits manufacturer statements about “green”

content by checking all raw materials and

fabrication process and gives a third party

certification on the product

• Cradle to Cradle is the most recognized

certification for the sustainably concerned

specifier

Beyond LEED – Cradle to Cradle Certified

Important components of Cradle to Cradle product certification:

• Using environmentally safe and healthy materials

• Design for material reutilization, such as recycling or

composting

• The use of renewable energy and energy efficiency

• Efficient use of water, and maximum water quality associated

with production

• Instituting strategies for social responsibility

Beyond LEED – Cradle to Cradle Certified

• The GREENGUARD Environmental Institute (GEI) is an

industry-independent, non-profit organization that oversees the

GREENGUARD Certification ProgramSM. As an ANSI

Authorized Standards Developer, GEI establishes acceptable

indoor air standards for indoor products, environments, and

buildings. GEI’s mission is to improve public health and quality

of life through programs that improve indoor air.

• The GREENGUARD Certification ProgramSM is an industry-

independent, third-party testing program for low-emitting

products and materials.

• All GREENGUARD Certified products are listed in the

GREENGUARD Online Product Guide, an indoor air quality

(IAQ) resource that is provided at no charge.

Beyond LEED – GREENGUARD Certified

Beyond Green - Durability

Recycled Content Surfaces The durability of buildings lies at the core of sustainable architecture,

yet it remains to be fully assessed as a measure of sustainability. Non-

durable building components, especially the envelope, result in high life

cycle costs due to maintenance, repair and premature replacement.

Durability should never be compromised when design decisions are

being made.

Beyond Green - Durability

Scratch Resistant • Scratching is probably the most prevalent problem that affects the

aesthetic look or wear on a surface.

• Recycled content products made with resin are extremely scratch

resistant–only quartz surfacing products would perform better.

• Just keep in mind, these products perform better than stainless steel,

natural stone, and solid surface, but they are not scratch proof!

• Resistance to scratch and wear is critical to keeping more surfaces

out of our future landfills.

Beyond Green - Durability

• Stain Resistant

• Heat and Scorch Resistant

Beyond Green - Performance

Maintenance Free When the only thing needed to clean the surface and maintain the

finish is warm water and, when absolutely necessary, only a very mild

detergent, there is no need to purchase, store or use harsh chemicals.

There will be no harmful residues left on the surface or VOC’s in the

air that can endanger the occupants or visitors.

And since the surface is non-porous, there is no periodic sealing

required. Thereby eliminating the cost of sealants (good ones are

very expensive), the cost of application, as well as eliminating VOC’s

and health issues that result from their use.

Design Options - Applications

• Vertical surfaces – Interior

• Walls

• Tiles

• Countertops

Design Options - Applications

2CM

EASED EDGE BULLNOSE EDGE

EASED EDGE BULLNOSE EDGE

Design Options - Edge Details

4CM

DEMI BULLNOSE EDGE BEVEL EDGE

DEMI BULLNOSE EDGE BEVEL EDGE

2CM

4CM

Design Options - Edge Details

AIA and FGI Draft

For The 2009 Edition of The Guidelines for Design and Construction of

Hospital and Healthcare Facilities A5.1.A1.e Preferred surface characteristics

(the ideal product):

1. Ease of maintenance, cleaning

and repair

2. Does not support microbial growth

3. Non-porous-smooth

4. Sound absorption/acoustic

5. Inflammable- Class I fire rating

or better

6. Durable

7. Sustainable

8. Low VOC/no off-gassing

9. Low smoke toxicity

10. Initial and life-cycle cost-effectiveness

11. Slip resistance-appropriate

coefficient of friction

12. Ease of installation, demolition,

and replacement

13. Non-problematic substrate

and/or assemblies

14. Seamless

15. Resilient, impact resistant

16. Control of reflectivity/glare

17. Option for color, pattern, and

texture

18. Non toxic/non-allergenic

AIA and FGI Draft

• The AIA does not endorse or promote any particular product, HOWEVER, the annual meeting between the national AIA committee and the Federal Guideline Institute develops the qualities, characteristics, and attributes that should be considered when specifying products. The IDEAL product would incorporate ALL of these attributes if possible.

• The list for the construction of Hospitals and Healthcare facilities (there are others for different type facilities/buildings) was chosen to use as an example because it has the harshest of environments and has the most demanding requirements

• Recycled surfacing products meet or exceed 17 of the 18 requirements. No other surfacing product does.

Conclusion

Conclusion

• Recycled Content Surfacing Products utilize and incorporate products

that have reached the end of their life-cycle. This means that

materials employed in the manufacturing of these surfacing products

cannot be incorporated into any other industrial product and would

otherwise collect in landfills.

• Look for products that have their recycled content listed by weight, as

this is a representation of the total product. If the labeling of a

surfacing product states 100% recycled glass, but only 10% of the

product is glass, it can lead to poor results for projects seeking LEED

certification.

• Some surfacing products offer up to 75% recycled content by weight

(40% Post-Consumer, 35% Post-Industrial)

Course Summary

Now, the design professional will be able to:

• Define the difference between “green” buildings and “green” products

• List the benefits of recycling

• Describe the basic content of recycled surfacing products

• Compare and contrast traditional surfacing materials to recycled

content surfacing products

• Describe how the manufacturing process of recycled content

surfacing materials can be environmentally responsible.

Course Summary

• Explain the advantages of resin-based recycled content surfacing to

other products that are typically specified

• Explain how recycled products can contribute (directly and indirectly)

to obtaining points under the LEED program

• Describe what Cradle-to-Cradle and GREENGUARD certifications

are and why they are important

• Explain the importance of specifying and using recycled content

surfacing products as related to environmental issues

• Explain the importance of going beyond “green”

GCS12A

Understanding Recycled Content Surfacing Materials:

Its value under LEED® and beyond

Credit for this course is 1 AIA/CES HSW/SD CE Hour

1 GBCI CE Hour For LEED Professionals

0.1 CEU for Interior Designers

© GreenCE, Inc. 2010

Barb Lyons Cosentino North America

13124 trinity drive stafford, tx 77477

281-380-9778 barbl@cosentinousa.com

Please note: you will need to complete

the conclusion quiz online at

greence.com to receive credit