| Dieser Datensatz ist Bestandteil der ÖKOBAUDAT. |
Process information
| Key Data Set Information | |
| Location | DE |
| Reference year | 2019 |
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| Use advice for data set | Scope: Shower surfaces, bathtubs and washbasins made of KALDEWEI steel enamel, exclusively manufactured in the Ahlen plant of Franz Kaldewei GmbH & Co. KG, Germany. System boundary: Type of EPD: cradle to gate – with options The LCA for the steel enamel shower surfaces, bathtubs and washbasins manufactured by KALDEWEI considers the life cycle phases of production (A1-A3) as well as recycling of packaging during installation (Module A5). Disposal in terms of reuse or treatment (C3) and landfilling (C4) is also considered in this study. An analysis of the modules under review gives rise to credits and debits beyond the system boundary (Module D), especially as a result of the steel recycling potential which is fully allocated to this module. Transport to the building (Module A4), dismantling at the end-of-life (C1), transport for the end-of-life (C2) and the use stage (Module B) are not considered in this study. |
| Technical purpose of product or process | Steel enamel shower surfaces, bathtubs and washbasins manufactured by KALDEWEI are used as self-supporting or non self-supporting elements in sanitary areas. |
| Classification number | 8.3.03 |
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| General comment on data set | Enamelled shower surfaces, bathtubs and washbasins consist of a deep-drawn body made of steel suitable for enamelling which is coated on both sides with base enamel and on the front with finishing enamel. The declared unit is 1 m² steel enamel for manufacturing Kaldewei shower surfaces, bathtubs and washbasins. The steel thickness and enamel thickness vary depending on the product. Accordingly, there are certain deviations for the specific product in terms of environmental impacts depending on the thickness of steel and enamel. |
| Copyright | Yes |
| Owner of data set | |
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| Time representativeness | |
| Data set valid until | 2024 |
| Technological representativeness | |
| Technology description including background system | The manufacturing process for enamelled shower surfaces, bathtubs and washbasins is subdivided into the following processes: - Manufacture of the steel blanks - Cleaning the blanks - Manufacture of the enamel frits - Manufacture of the enamel slips - Enamelling The process steps associated with these sub-processes are outlined as follows: 1. Manufacture of the steel blanks The blanks are manufactured in automatic, continuous press lines in the following process stages: · Deep-drawing: The blanks acquire the required shape by deep-drawing electrostatically-oiled steel blanks in 2-part drawings with forces of 8,000–10,000 kN. · Processing the blank: After deep-drawing, the outlets, overflows and sometimes holes for handles are punched in the blanks and the base frame brackets mounted. · In the case of bathtubs with panelling, these are welded on after deep-drawing the bathtub blanks. · In the case of wall-mounted washbasins as well as built-in and top-mounted washbasins, the washbasin edges are welded. · Working the edges of the raw bath/tray: The edge contours of the raw bathtubs/trays are produced by folding over and trimming the edges in several steps. 2. Cleaning the blanks The raw steel bathtubs and trays are cleaned in a continuous, automated facility according to the following sub-steps: · Degreasing the blanks: After they have been produced, the blanks are covered with a film of corrosion-protection oils, deep-drawing oils and abraded metal particles from the deep-drawing process which are washed off by spraying them with alkali tenside solutions. · Acidic rinsing of the blanks: Any impurities remaining on the blanks after degreasing are washed off by spraying with a strongly-diluted solution of sulphuric acid. · Alkali rinsing of the blanks: A temporary rust-inhibiting layer is formed on the blanks by spraying them with a slightly alkaline amine solution. 3. Manufacture of the enamel frits Enamel frits are the glass granulate used for enamelling and are produced in the following sub-steps: · Formulation and mixing of the raw materials for the glass: The raw materials for the glass are weighed and mixed in mixing plants. · Smelting the enamel frit: The raw material mixtures for the glass are smelted in batch-type smelters for 2-3 hours at temperatures of between 1100 and -1300 °C. When the smelting process is complete, the glass melt is poured into water to quench it and thus granulated. · Drying the enamel frit: The surface water adhering to the grains of the enamel frit is partially removed by drying. 4. Manufacture of the enamel slips Enamel slips are the suspensions of glass granulate in water used for enamelling and are produced in the following sub-steps: · Formulation of the raw materials for the slip: Solid raw materials are weighed and filled into batch-operated mills along with the liquid, volumetrically-dosed raw materials. · Grinding process: The raw materials for the slip are ground to enamel slips in drum mills. · Preparation of the enamel slips: After the grinding process, the enamel slips are pumped through systems of sieves and magnetic separators in order to separate off coarse mechanical and magnetic metallic impurities. 5. Enamelling Enamelling is the production of a layer of glass on a metal surface and is carried out in the following sub-steps: · Coating the cleaned blanks with enamel slip: Robots in automatic spray booths spray the fronts and backs of the blanks with enamel slips. · Drying the enamel coating: The water remaining in the enamel coating is evaporated in continuous drying ovens. · Firing the enamel coating at 820-860 °C: The enamel coating is fired onto the blanks in continuous furnaces so that the coating on the upper side of the washbasin or bathtub/tray has a thickness of 200-300 μm. · Packaging: An automated system applies the company logo before the enamelled parts are packaged. Technical data: The products consist of a deep-drawn body made of steel suitable for enamelling which is coated on both sides with base enamel and on the front with finishing enamel. The following chart depicts sample data on some shower surfaces, bathtubs and washbasins. For KALDEWEI products, the ratio of bathtub/tray surface to the projection surface is determined as follows: For bathtubs: bathtub surface [m²] ~ 1.5 x projection surface [m²] + 0.5 [m²] For shower trays lower than 140 mm: tray surface [m²] ~ 1.14 x projection surface [m²] + 0.06 [m²] For shower trays with a depth of 140 mm: tray surface [m²] ~ 1.24 x projection surface [m²] + 0.13 [m²] For shower trays with a depth of 250 mm: tray surface [m²] ~ 1.45 x projection surface [m²] + 0.24 [m²] Built-in and under-counter washbasins: washbasin surface [m²] ~ projection surface [m²] x 1.19 + 0.02 [m²] Wall-mounted and top-mounted washbasins: washbasin surface [m²] ~ projection surface [m²] x 1.86 + 0.04 [m²] Bathtubs with panelling: bathtub surface [m²] ~ projection surface [m²] x 1.5 + panelling length [m] x bathtub height [m] 0.5 [m²] The basis weight of the steel body used for enamelling is 18 to 22 kg/m² for shower surfaces and bathtubs, 10 to 11 kg/m² for bathtubs with a reduced steel thickness (primarily for export), and 15 to 21 kg/m² for washbasins. Depending on the respective model, features and construction specifications on the test bench, KALDEWEI shower surfaces, bathtubs and washbasins comply with individual or several sound insulation standards. These include DIN 4109, DIN 4109/A1, VDI 4100 SST I-III and SIA 181. All sound insulation certificates are available on www.kaldewei.de. The maximum service temperature of the enamelled steel parts is significantly higher than 500 °C. The enamel is at least 0.2 mm thick on the upper side. The optional enamel-based "Anti-slip", "Full anti-slip" or "KALDEWEI SECURE PLUS" surface finishes comply with evaluation group B for wet-loaded barefoot areas /DIN 51097/ and evaluation group R 10 for anti-slip properties in workrooms and fields of activities with increased risk of slipping /DIN 51130/. Declared unit: 1m2 of surface of the declared average product weighs 17.93 kg. The average basis weight of steel is 16.64 kg/m². This gives rise to an average calculated steel thickness of 2.1 mm for these products. The average basis weight across the various products is 1.29 kg/m² for enamel. This gives rise to a calculated enamel thickness of 517 µm, including enamelling on the front and back. |
| Flow diagram(s) or picture(s) | |
Modelling and validation
Administrative information
Environmental indicators