On-site Wastewater Treatment: Alternatives Offer Better Groundwater Protection

Feature

On-site Wastewater Treatment: Alternatives Offer Better Groundwater Protection

Conventional in-ground wastewater disposal systems cannot be counted on to adequately protect groundwater. It surprises many people to learn that even a properly functioning septic system built to code is designed to introduce pollutants into the soil and—ultimately—the groundwater. Worse, a large number of the roughly 22 million in-ground wastewater systems in this country are either inadequately designed or failing.

We can do a lot better. Interest is rapidly growing in a number of alternatives to conventional in-ground wastewater disposal systems. These alternatives include on-site composting of toilet wastes with graywater separation, constructed wetlands, and sand filters. We are just beginning what is likely to be a wholesale shift in the way we design on-site wastewater disposal systems. This article takes a look at conventional septic systems and describes three environmentally preferable alternatives. Municipal sewage treatment is not addressed.

Conventional Septic Systems

To understand why conventional in-ground treatment and disposal systems do not effectively treat wastewater, you have to know something about how they work and what they’re treating.

Wastewater includes a number of significant contaminants. The most commonly measured components of wastewater are biochemical oxygen demand (BOD), suspended solids, nitrogen, phosphorous, and coliform bacteria. BOD is the amount of organic matter present based on the amount of oxygen required by microorganisms to decompose it. BOD5 is a measure of that demand over a five-day period. Fecal coliform are bacteria that live in the human digestive tract; while not dangerous themselves, they serve as indicators of pathogens that might be present.

Table 1. Average Pollutant Loading in Residential Wastewater

*Coliform concentrations in number of organisms per liter

Source: Manual of Wastewater Treatment/Disposal for Small Communities, U.S. Environmental Protection Agency, September 1992.

Table 2. Bacteriological Characteristics of Graywater

[enlarge image]

* Studies from 1978 to 1990. It is believed that kitchen sink wastes are not included in these figures.

† Samples from bathtub or shower

‡ Samples from washing machines

Source: National Association of Plumbing-Heating-Cooling Contractors, Assessment of On-Site Graywater and Combined Wastewater Treatment and Recycling Systems, August 1992.

Wastewater contaminants can be measured by concentration in wastewater (milligrams per liter, or numbers per liter), or by how much is produced per person in the building (grams per capita per day). Typical contaminant levels in residential wastewater are shown in Table 1.

Surprisingly,

graywater (usually defined as all wastewater except that from toilets) typically introduces more BOD5 and almost as much suspended solids as black­water—even if garbage disposal output is not included in the graywater component. Studies of microorganisms in blackwater and graywater have produced highly variable results. Results of three studies of bacteria in graywater are shown in Table 2.

While graywater clearly contains high levels of organic matter, some claim that the organic matter (BOD) in graywater is different from that in blackwater. In a report

Using Greywater: A Basic Planning Manual for the Processing of Greywater, Clivus Multrum, Inc. presents evidence from Europe that the organic matter in graywater breaks down much faster (almost 65% per day) because it is more readily available to microorganisms.

In a conventional septic system, wastewater flows from the building into a septic tank where solids settle out. The bacteria in the septic tank’s anaerobic environment carry out some biological decomposition, but most of the contaminant removal occurs when the material that settles to the bottom of the tank (septage) is pumped out. Based on limited studies presented in the EPA

On-Site Wastewater Treatment and Disposal Systems Manual, BOD5 concentrations are reduced 30% to 70% in septic tanks, suspended solids concen­trations are reduced 60% to 90%, total nitrogen levels are reduced 30% to 40%, and phosphorous levels are reduced about 15%.

Effluent passes from the septic tank to a drainfield (sometimes called an absorption field or leaching field). There the effluent seeps into the ground where aerobic soil bacteria break down most of the organic matter, including pathogens. If the percolation rate is too great, however, or either air or soil bacteria are limited, BOD may not be adequately removed. If high-BOD effluent makes its way to surface water (streams, ponds, etc.), it can use up oxygen in those bodies of water. With inadequate oxygen, fish die and anaerobic bacteria take over, resulting in stagnant, smelly conditions. Over time, an anaerobic biomat may also form in the drainfield, restricting effluent flow and leading to system failure.

Even a properly functioning drainfield does not remove most nutrients (nitrogen and phosphorus). These are among the most harmful pollutants in wastewater because if they reach surface waters (streams, ponds, etc.), they fertilize algae, whose growth can cause eutrophication. In this process, prolific algae growth covers the surface of the water, blocking sunlight penetration into the water. Without sunlight, underwater plants cannot carry out photosynthesis. As the plants die and decay, oxygen in the water is used up, killing fish and most other freshwater life. This result is similar to that described above with BOD pollution, but its effects are usually even more severe.

Along with contaminating bodies of water, high nitrogen levels in drinking water can cause problems. According to Sherwood Reed, P.E., of Norwich, Vermont, a leading authority and EPA consultant on wastewater disposal, “there are groundwater resources all over the country that are contaminated with nitrate.” Reed considers it a virtual certainty that in any village center in New England where in-ground septic systems are used, the nitrate level in groundwater will exceed federal drinking water standards (10 mg/l). For infants, nitrate poisoning is a significant risk, causing methemoglobinemia (blue baby syndrome), and some people consider high nitrate levels to be carcinogenic.

The other problem with conventional on-site wastewater systems is septage disposal. Standard practice today is to pump it out and take it to a municipal sewage treatment facility. Even though sewage treatment plants often do a pretty good job at removing pollutants from water, large quantities of sludge are produced that require landfilling, surface application to land, or incineration. Contaminants other than those from human waste and household cleaning products end up in municipal sewage sludge, making it unsuitable for many applications.

Given these problems with conventional on-site wastewater treatment, environmentally concerned designers and builders should consider alternatives. Three alternatives to conventional in-ground wastewater treatment and disposal are discussed below. Each provides significant environmental advantages over conventional systems.

Composting Toilets

A properly managed composting toilet offers the most environmentally attractive option for treating and disposing of human waste. The basic strategy is to keep human wastes totally separate from graywater. As soon as you mix human excrement and urine with water, according to Abby Rockefeller, president of Clivus Multrum, Inc., treatment becomes more complex and expensive. By biologically breaking down the wastes, nutrients can be returned to the land as fertilizer. Perhaps most important, there is no septage that needs to be treated and/or disposed of off-site.

There are several different types of composting toilets (referred to as biological toilets by some, since true, high-temperature com­­pos­t­ing conditions are not reached). The most familiar composting toilet is the Clivus Multrum, introduced in the United States in the early 1970s. It has a large holding tank situated directly beneath the toilet—usually in the basement. Human wastes mixed with kitchen compost and other high-carbon material, such as peat moss, accumulate in the tank where aerobic bacteria, worms, and other organ­isms break down the wastes over a period of months. Humus is removed at the bottom end after a 6- to 12-month retention time. Most liquids evaporate and exit through the ventilation stack, though a recent design change provides for separate collection of liquid (compost tea), which the company describes as an odor-free, high-nutrient fertilizer. A residential-sized Clivus Multrum composting toilet costs $2,000 to $3,000 (plus shipping and installation), depending on size and features.

A second type of composting toilet is smaller and more compact.

Human wastes and organic matter (toilet paper and peat moss) are mixed in the holding tank. Ventilation provides oxygen for aerobic bacteria, liquids evaporate and exit through the vent stack, heat is provided by compost action and a supplemental heater, and periodic mixing is done automatically or with a hand crank. Humus is removed via a special drawer every few months as required. Some of these systems can be used with ultra-low-flush (1 pint per flush) toilets. Sun-Mar, the leading producer of these toilets, offers models ranging in price from $1,000 to $1,300.

A third type of composting toilet is more high-tech. The AlasCan composting toilet and graywater treatment system was introduced in the late 1980s for use in permafrost regions and is more automated and “lifestyle independent” than other composting toilets—but also more complex and expensive. An ultra-low-flush toilet is used to deliver wastes to a tank located in the basement. Kitchen food wastes are delivered to the composting toilet after shredding in a garbage disposal, and additional wood chips or coarse sawdust is added. In the heavily insulated tank, bacteria, worms, and other organisms break down organic matter. There is a water recirculation system that collects water at the bottom of the tank and returns it to the organic matter. Automatic agitators mix and aerate the material, and an air-to-air heat exchanger exhausts air and delivers preheated fresh air. Total system cost for an AlasCan toilet and graywater system is $9,000 to $10,000, plus shipping and installation.

Dealing With Graywater

Composting toilets effectively deal with human wastes but not graywater. Both Clivus and AlasCan offer systems for treating graywater. The AlasCan system is fully integrated and even provides for delivery of sludge from the graywater settling tank into the composting chamber.

There is growing interest in graywater separation and use, particularly in drought-prone areas of the country. With fairly simple treatment, proponents argue, graywater can safely be used for landscape irrigation and toilet flushing. The National Association of Plumbing-Heating-Cooling Contractors in Falls Church, Virginia, one of the nation’s four model-plumbing-code-writing associations, is heavily involved in advancing graywater separation and use. Reuse of graywater will be addressed in greater detail in a future article.

Issues of Concern with Composting Toilets

1.

Graywater treatment/disposal is still required. Most codes around the country currently require that graywater be treated just the same as blackwater (i.e., same size septic tank and drainfield), so there are no savings to pay for the composting toilet. Revisions to plumbing codes are gradually changing this situation.

2.

Performance depends on the operator. Unlike conventional flush toilets, composting toilets require proper management to function as designed. Organic matter needs to be added, some systems require periodic mixing, and you have to be careful about what goes in.

3.

Potential for overfertilizing. The humus and compost tea from composting toilets have very high nutrient concentrations and must be carefully applied to prevent nutrient build-up. They are most appropriately used where nutrients will be removed through harvesting—not in natural ecosystems.

4.

Concern about pathogens or toxins in composted waste. Composting toilets do not reach high enough composting temperatures to guarantee destruction of all pathogens. Experts recommend against direct application to vegetable crops, or at least root crops. The optimal strategy may be to apply this fertilizer on cover crops used in rotation, on tree crops, or on nonfood crops (nursery stock, ornamentals, etc.).

5.

Unconventional and requires homeowner involvement. As a society, we don’t like to think about our excreta, and the thought of keeping it in our houses just doesn’t feel right to most people. More than any other reason this is why composting toilets have not caught on more widely—and are unlikely to do so. Composting toilets will probably find much greater use in public buildings, such as park facilities.

6.

Energy use. Composting toilets use energy to operate ventilation fans and, in some cases, heaters, agitators, and other mechanical equipment. Over the course of a year, a continually operating fan—even a small one—uses a lot of electricity. Ventilation will also increase heating and cooling loads.

Constructed Wetlands

Constructed wetlands are the newest, and in many ways most exciting, alternative to conventional on-site wastewater treatment. They are exciting because they so closely mimic natural systems in their operation, harboring diverse, complex ecosystems. By constructing artificial wetlands, we also learn more about the value of

natural wetlands—and why we need to protect them.

The idea of building artificial wetlands specifically for wastewater treatment dates back to the late 1960s in Germany, but did not gain significant attention until the 1980s. They are used today both for municipal sewage treatment and for on-site treatment. In the U.S., the first work with constructed wetlands wastewater treatment was done in the early 1980s.

Some of the earliest work was done by NASA at the Stennis Space Center in Mississippi, and by Dr. B. C. Wolverston in Picayune, Mississippi. They termed this system a

microbial rock plant filter. Constructed wetlands expert Sherwood Reed estimates that there are 500 constructed wetland systems in operation in the U.S. today, one-half to two-thirds of which are on-site treatment systems, the rest municipal.

Constructed wetland designs are evolving at a rapid pace based on on-going research. While some constructed wetlands have exposed surface water,

subsurface-flow wetlands are more practical for on-site wastewater treatment. Because water is never at the ground surface, mosquito breeding, odor, and risk of human contact with effluent are effectively eliminated. A typical system is shown in the illustration on page 15. The wetland is one to three feet deep and built with an impervious bottom and sides—usually a plastic pond liner or poured concrete. Effluent from the septic tank is introduced on one side of the wetland through diffusing pipes, and the liquid flows through a layer of clean, washed gravel (1/2" to 1" diameter) in which emergent wetland plants are growing. The most common plants for constructed wetlands are common reed (Phragmites), cattail (Typha), pickerelweed (Pontederia), arrowhead (Sagittaria), and bullrush (Scirpus), but others can be used.

While early constructed wetlands tended to be quite deep, recent research has shown that most root growth and biological activity is concentrated in the top foot. Wetland plants, because they are adapted to growing in stagnant water, have developed mechanisms to deliver oxygen (required for respiration) to their roots. Bacteria living in association with plant roots do most of the work breaking down pollutants and organic matter. A total hydraulic retention time of one to seven days is typical, though longer retention times during colder winter months are often desirable. Water depth in the gravel is typically controlled by outlet valves .

Nitrogen removal in wetlands is accomplished through several different biochemical steps.

Ammonification is the conversion of organic nitrogen-containing compounds such as amino acids into ammonia (NH3).

Nitrification, which requires aerobic bacteria, is the conversion of ammonia into nitrate (NO3); this can occur near the wetland plant roots where oxygen is pumped down into the wetland.

Denitrification is an anaerobic process in which bacteria convert nitrate into atmospheric nitrogen (N2)—a harmless component of our atmosphere. Finally, plants can take up either ammonia or nitrate and incorporate it into their tissue. For nitrogen to be removed from constructed wetlands by this last process, however, the plants must be harvested. Even in wetlands where plants are harvested, studies have shown that less than 10% of the nitrogen goes into plant tissue; most goes into the nitrification-denitrification reactions of bacteria.

With on-site wastewater treatment systems, the treated effluent is usually collected at the outlet side of the wetland and then delivered (by gravity or pump) to the drainfield. In other words, the entire constructed wetland is an intermediate step between the septic tank and the drainfield. The advantage is that the effluent reaching the drainfield is much cleaner and less likely to pollute the groundwater. Because the effluent from a constructed wetland is so much cleaner than effluent from a septic tank, reasonable arguments can be made for downsizing the drainfield, the savings from which can pay for some of the cost of the wetland. Whether or not the drainfield can be downsized depends on the wastewater flow (hydraulic loading rate), soil characteristics, and local codes.

As for how effective constructed wetlands are at removing pollutants from wastewater, we still do not have good answers. The July 1993 EPA report,

Subsurface Flow Constructed Wetlands for Wastewater Treatment: A Technology Assessment, provides the most complete overall picture of performance. BOD removal is excellent, with effluent levels well below the 20 mg/l reference level commonly used in assessing wastewater effluent quality, and often well below 10 mg/l. Interestingly, much of the BOD measured in constructed wetland effluent may come from the wetland itself, not the

wastewater.

Total suspended solids removal is also very good, with effluent levels typically less than 10 mg/l. Nitrogen removal is more variable. Most organic nitrogen is converted to ammonia. Nitrification and denitrification reactions depend on the bacterial ecosystems in the wetlands. A lot of attention is going into design of wetlands specifically to achieve good nitrogen removal—such as shallower bed design and strategies to achieve deeper root penetration.

Constructed wetlands are most widely used in the southern part of the U.S. (especially Kentucky, Louisiana, and Mississippi), but their viability in more northern climates is being increasingly demonstrated. Sherwood Reed has recently designed a residential-scale system for Burlington, Vermont, and Southwest Wetlands Group, Inc., of Santa Fe, New Mexico, has designed systems in Wyoming, Montana, Michigan, Rhode Island, Vermont, and Massachusetts. For northern climates, somewhat deeper systems are often needed to prevent freezing. It may also be necessary to partition the wetland so that flow in one section can be increased in the winter to prevent freezing, a strategy Reed used in his Vermont system.

Costs of constructed wetlands are highly variable and site-specific. In 16 residential-sized constructed wetlands in an Alabama demonstration program financed by the Tennessee Valley Authority (TVA), installed costs, including septic tanks, ranged from $2,550 to $10,020, with an average of $6,120, of which $2,070 was for labor (design fees were not included in the costs). Hydraulic loading rates for these systems ranged from 83 gallons per day (gpd) to 600 gpd, and constructed wetlands ranged in area from 108 ft2 to 784 ft2.

Issues of Concern with Constructed Wetlands

1.

Designs are not standardized. Except for a TVA design manual (see EBN

Vol. 3, No. 1), there are few specific design guidelines, let alone off-the-shelf constructed wetland designs available. At present, each system must be custom designed.

2.

Freezing potential in northern climates. If wastewater flow rates are low, the constructed wetland shallow, or snow cover absent, the system could freeze in very cold conditions. There is currently very little experience with these systems in northern climates.

3.

Reduced performance in cold weather. Biological processes slow down as temperatures drop. In northern climates this could result in higher pollution concentrations being introduced to the drainfield during the winter months.

4.

Operation and maintenance required. Constructed wetlands are complex ecosystems. Climate and operating conditions may change the performance of the system (drought, heavy rains, changing wastewater flows, etc.).

5.

Systems not recognized in codes. Even though good arguments can be made for permitting, smaller drainfields when effluent flows through constructed wetlands, this is not yet accepted in most areas, making economic justification difficult.

6.

New technology. There is still very little operating and performance experience with constructed wetlands.

7.

Septage still a problem. Septic tanks are still required with constructed wetlands, and the residual solids from septic tanks have to be treated and disposed of.

Sand Filters

Sand filters have been around for almost a century, but until recently have seldom been used as a component of in-ground wastewater treatment systems. They function somewhat like constructed wetlands, but are smaller and provide a more controlled bacterial environment. The most common type of sand filter is installed between the septic tank and the drainfield (see illustration). Effluent from the septic tank periodically doses the top surface of the sand filter and percolates through the sand (usually about 24" deep) where aerobic bacteria break down organic matter and nitrify the ammonia. Beneath the sand layer is a gravel layer where effluent is collected and delivered by gravity or a pump to the drainfield. A liner on the bottom and sides of the sand filter contains the effluent. The entire filter is covered with filter fabric and a thin layer of soil planted with grass. Because the septic tank effluent is delivered in doses, the system is called an intermittent sand filter. In some designs the effluent is recirculated back through the sand filter several times.

More than 10,000 intermittent sand filters have been installed in the states of Oregon, Washington, and California since 1976. Orenco Systems, Inc., of Roseburg, Oregon, is the leading designer and supplier of sand filter components. Most installed systems are 360 ft2 (10' x 36' or 18' x 20'), the “one-size-fits-all” standard for the state of Oregon. Experimental systems are being installed in Washington, Alaska, Massachusetts, and British Columbia with filters as small as 100 ft2.

Sand filters are very effective at removing BOD, suspended solids, and fecal coliform, and they convert most ammonia to nitrate. Because of the effluent purity from sand filters, the drainfield can be significantly downsized, according to proponents. Biomats do not form in the drainfields, and absorption rates are higher than with conventional septic tank effluent. The state of Oregon now permits a 70% reduction in drainfield area with the standardized “Oregon Intermittent Sand Filter,” and Washington permits a 50% reduction. Orenco Systems has been testing a very shallow drainfield design with no imported rock fill.

The installed cost of a sand filter and shallow drainfield (including septic tank) is about $6,000, according to Orenco. The extra cost of adding a treatment step between the septic tank and the drainfield should be offset by the greatly reduced cost of the drainfield, though downsizing the drainfield is not yet acceptable in most states. In situations where this approach might obviate the need for a raised-bed drainfield, significant savings could be achieved.

Trickling Filters

Along with pioneering work with intermittent sand filters, Orenco has been testing a trickling filter that is integrated with the septic tank.

The system was developed specifically to reduce nitrogen levels in effluent from intermittent sand filters, and the company expects to introduce it this spring. With this system, effluent in the septic tank is continually pumped into a small trickle filter located above the septic tank (see illustration). The effluent trickles through the filter, and bacteria remove nitrogen through nitrification and denitrification processes. These two nitrogen-removal reactions can occur because the trickling filter operates aerobically, while the septic tank itself is anaerobic. Cost of the trickling filter add-on to a septic tank is expected to be in the range of $500 to $600.

Issues of Concern

with Sand Filters

1.

How small can intermittent sand filters be made without sacrificing performance? If they can be made small enough to be delivered by truck and filled with sand on-site, cost may come down substantially.

2.

Intermittent sand filters, recirculating sand filters, and trickling filters are mechanically complex. What will the long-term durability of components be? How repairable will they be?

3.

Septic tank quality. To function properly, sand filters require watertight septic tanks, and experience is showing that in many parts of the country, tanks are not watertight. Significant improvements in septic tank manufacturing and quality control are needed.

4.

Energy requirements. Although passive siphon-dosing systems can be designed in some situations, most intermittent sand filters and all recirculating sand filters require pumps. Electrical consumption may be significant over time.

5.

Septage still a problem. Septic tanks are still required with sand filters, and the residual solids from septic tanks have to be treated and disposed of.

Conclusions

A number of factors are pushing us in the direction of improved on-site wastewater treatment systems. First, there are high levels of nitrate pollution from septic systems in more populated village centers throughout rural America. Second, we are learning more about the biochemistry of wastewater treatment and can design artificial ecosystems to remove selected pollutants. Third, funding for improvements to municipal wastewater treatment plants reverted from the federal government to state and local governments during the 1980s; more and more communities cannot afford proper municipal sewage treatment and are looking for on-site alternatives.

This article has reviewed several wastewater treatment alternatives, but by no means all of the available options. Exciting work is being done by Dr. John Todd and his consulting firm, Living Technologies, in Burlington, Vermont, on Solar Aquatic Systems. These systems treat wastewater as it cascades through containers of water rich with aquatic life. Another approach is to use mechanical aeration chambers to support aerobic bacteria. Though energy-intensive and mechanically complex, this system provides a reasonable alternative to conventional in-ground septic systems in some situations.

In considering our wastewater disposal problems, a whole new paradigm emerges: the idea of looking at wastewater as a usable resource instead of simply waste. From an environmental standpoint, composting toilets and separate treatment and use of graywater probably offer the best option. Useful fertilizer is produced, water use is dramatically reduced because conventional flush toilets are eliminated, and there is no residual septage to treat or dispose of. Unfortunately, if experience to date with composting toilets is any indication, we are unlikely to see wide acceptance of these systems.

For most clients, it will continue to make the most sense to keep the graywater and blackwater combined and use either a constructed wetland or sand filter to provide treatment. We still have a lot to learn about the design and operation of these alternative systems, but enough systems have now been installed and are operating successfully that we can begin using them more widely. As we learn more, it is likely that designs will be simplified, standardization will occur, and costs will come down.

A very exciting aspect of these alternative strategies is that we can begin integrating wastewater treatment and disposal systems into the landscaping around buildings—a concept that opens up all sorts of potential. We can treat the wastewater enough to use it safely for irrigation. Constructed wetlands can become valuable assets to the landscaping around buildings—especially if we call them “flower beds.” It is quite conceivable that within a few years it will be landscaping professionals who deal with wastewater treatment, not sanitary engineers.

For more information:

AlasCan, Inc.

3400 International Way

Fairbanks, AK 99701

907-452-5257

Canada Mortgage and Housing Corporation (CHMC)

700 Montreal Road

Ottawa, ON K1A 0P7 Canada

613-748-2000

Clivus Multrum, Inc.

104 Mount Auburn Street

Cambridge, MA 02138

800-425-4887, 617-491-0053 (fax)

Living Technologies

431 Pine Street

Burlington, VT 05401

802-865-4460, 802-865-4438 (fax)

National Association of Plumbing-Heating-Cooling Contractors

PO Box 6808

Falls Church, VA 22046

800-533-7694, 703-237-7442 (fax)

National Small Flows Clearinghouse

West Virginia University

PO Box 6064

Morgantown, WV 26506-6064

800/624-8301, 304/293-3161 (fax)

Orenco Systems, Inc.

2826 Colonial Road

Roseburg, OR 97470

503-673-0165, 503-673-1126 (fax)

Southwest Wetlands Group

PO Box 9280

Santa Fe, NM 87504

505/988-7453

Sun-Mar Corp.

5035 N. Service Road, C2

Burlington, ON L7L 5V2 Canada

416/332-1314, 416/332-1315 (fax)

Tennessee Valley Authority

Water Management Resources Group

1101 Market Street

Chattanooga, TN 37402

615-751-7314, 615-751-7479 (fax)

US EPA

ORD Research Information

26 West Martin Luther King Drive

Cincinnati, OH 45268-1072

513-569-7562

Published March 1, 1994

(1994, March 1). On-site Wastewater Treatment: Alternatives Offer Better Groundwater Protection. Retrieved from https://www.buildinggreen.com/departments/feature

Heating Fuel Choices: Weighing the Alternatives

Feature

Heating Fuel Choices: Weighing the Alternatives

The energy used for space heating and cooling in residential buildings produces 420 million tons of carbon dioxide per year and 8.9 million tons of atmospheric pollutants.

Published November 1, 1993

Cellulose Insulation: An In-Depth Look at the Pros and Cons

Feature

Cellulose Insulation: An In-Depth Look at the Pros and Cons

Should we be recommending cellulose to our clients? If so, on what basis? If not, why—what are its drawbacks?

Cellulose insulation has been the darling of the green building movement because of its recycled content, low embodied energy, low-tech processing, and excellent energy conservation performance. But concerns are also raised about health risks for cellulose installers and occupants of cellulose-insulated buildings. In fact, some healthy home advocates strongly discourage its use. Should we be recommending cellulose to our clients? If so, on what basis? If not, why—what are its drawbacks? EBN took an in-depth look at these questions, and we report here on our findings.

 

Manufacturing

Cellulose insulation is a fairly simple material produced from one of our biggest solid-waste products: newspaper. The 70 to 80 cellulose insulation manufacturers in North America purchase old newspaper that has been collected through recycling programs. There are two stages of production, according to Doug Leuthold of Advanced Fiber Technology, a company that makes cellulose insulation manufacturing equipment. In the first, the newspaper is chopped into pieces from one to several inches in diameter. The second stage (finishing mill) differs considerably from one manufacturer to another. The oldest and most common finishing mill is a hammer mill in which swinging metal plates attached to a rotating shaft beat the newspaper in a chamber until the pieces are small enough to fall through a screen. The maximum size of cellulose particles produced in the hammer mill is typically 38” to 14”. Disk refiners are a little different; the chopped newspaper is shredded as it falls between two rotating plates. A third, newer, process is known as fiberization. Instead of cutting the paper, fiber­ization actually disaggregates it back into individual fibers. In the fiber­ization process developed by AFT, high-pressure air is used to “blow particles apart,” says Leuthold. “You end up with a fluffy product that looks like the padding in disposable diapers, except that it’s gray.” Fiberization produces lower-density cellulose with a number of advantages.

Once the newspaper has been adequately shredded, chemicals are added to provide fire-retarding and mold-inhibiting properties to the insulation. The most common chemicals used today are boric acid, sodium borate (borax), and ammonium sulfate. Boric acid and sodium borate have the advantage of not only providing fire retardancy, but also adding mold, insect, and rodent resistance to the insulation. Aluminum sulfate has been used in the past as a fire retardant, but is rarely if ever used today, according to Daniel Lea of the Cellulose Insulation Manufacturers Association, or CIMA. Most manufacturers use a mixture of borates and ammonium sulfate, and some add small quantities of several phosphates. According to Dave Yarbrough at Oak Ridge National Laboratory, there is a trend in the industry to replace some of the borate with ammonium sulfate, because the latter is less expensive. After the insulation is mixed with fire-retardant chemicals—and in some products dry binders—it is bagged and shipped to building supply outlets or installers.

 

Installation

There are a number of ways to install cellulose insulation. The oldest and simplest use is loose-fill cellulose in attics. The insulation is blown or poured into the attic space where it provides about R-3.7 per inch. Dry-blown cellulose is also installed in walls as a retrofit insulation material. Holes are typically drilled through the exterior sheathing after removing several sections of siding, and the cellulose is blown in.

Wet-spray cellulose, as the name implies, has water added during installation to make it stick when blown into wall cavities (binders are sometimes used as well). Conventional wet-spray cellulose using a hammermill product is usually installed quite wet—sometimes with more than 100% water on a “dry-weight” basis (weight of water divided by weight of dry cellulose), or about four gallons of water per 30-pound bag. By using fiberized cellulose instead of hammermill cellulose, the water content can be significantly reduced. American Environmental Products (AEP), a Virginia cellulose manufacturer, has gotten the moisture content down to about 28% (dry-weight basis), according to Ivan Sandau of AEP. The company offers cellulose either with or without a dry binder. The binder, described as an organic product approved as an agricultural food additive, is activated upon contact with water.

Another relatively new formulation of cellulose insulation, referred to as

stabilized cellulose, is used in attics. This product has a binder in it and is applied with a small quantity of water. The binder prevents settling, which may otherwise reduce the installed thickness of loose-fill cellulose insulation by as much as 25%. American Environmental Products, one of several manufacturers producing stabilized cellulose, achieves a 1.3 lb./ft3 density with its stabilized attic insulation.

Two other approaches used for walls do not require water. In the dense-pack process, cellulose is blown into closed wall cavities at a relatively high density of 3 to 312 lbs./ft3. Because of the high density, settling does not occur. With the other approach, installers use forms to blow dry cellulose into open wall cavities. The forms, which are propped against the inner side of stud bays, hold the insulation in place as it is installed, and the insulation stays in place after forms are removed and until the inner wall surface is installed.

 

A Market for Recycled Newspaper

 

North America produces roughly 13 million tons of newspaper each year—about 100 pounds per person. Fifty-five percent of this is currently recycled (1992) according to the American Forest and Paper Association; the rest accounts for about 4.6% of municipal solid waste. While these statistics are a big improvement over ten years ago when newspaper accounted for 8% of our municipal solid waste, we still landfill or incinerate a huge amount.

There are various ways old newspaper can be recycled. The biggest use, turning it back into new newspaper, requires significant processing (de-inking and bleaching, for example), which takes a lot of energy and produces contaminated water that must be treated. Recycling old newspaper into cellulose insulation is much simpler: de-inking is not required, there is no pollution generated in the process, and very little energy is used.

According to CIMA, 414,000 tons of cellulose insulation were produced in 1990. Because the finished product is approximately 80% recycled newspaper by weight, this means that cellulose insulation currently provides a use for roughly 330,000 tons of old newspaper. This represents 4.6% of total recycled newspaper (see pie chart). On a volume basis, EBN estimates that cellulose currently has about 10% of the fiber insulation market (fiberglass, mineral wool, cellulose). Increasing the market share of cellulose insulation—and thus increasing the use of recycled newspaper—will further strengthen markets for recycled newspaper, which will improve the economic viability of recycling programs. (Today, municipalities often have to pay to get rid of the newspaper they collect through recycling because the markets for recycled newspaper are so weak.)

 

Limited Boron Supplies?

While the primary ingredient in cellulose insulation is in bountiful supply, the second-most-used ingredient may not be. In North America, borax crude was first mined in Death Valley, California, in 1883, using 20-mule-team wagons (made famous by the television program "Death Valley Days"). A far larger borate ore deposit was discovered in 1925 in the Mojave Desert near Boron, California, and production today is about 10,000 tons per day from an open-pit mine. Since then, no additional borate reserves have been discovered. A source in the company estimated that reserves will last only about 50 years at today’s consumption level. U.S. Borax currently accounts for about 50% of world borax production; the only other major source is in Turkey.

 

Low Embodied Energy

Because cellulose insulation production is such a simple, low-tech process, manufacturing plants can be small and widely scattered. That means transportation energy can be kept low. By contrast, fiberglass manufacturing is far more complex and requires heavy capitalization and centralized production (i.e., longer shipping distance).

 

Comparing the Embodied Energy of Cellulose and

Other Insulation Materials

Embodied energy figures (other than cellulose) from a 1991 study by Franklin Associates for the Society of the Plastics Industry

The only estimates of embodied energy in cellulose insulation EBN found were from Canadian manufacturer Therm-O-Comfort Co., Ltd. In a 1991 letter to the Canadian Standard Association, Therm-O-Comfort estimated primary energy consumption for cellulose insulation to be 85 kWh/ton (145 Btu/lb.). This figure does not account for the fire-retardant chemicals or transportation energy. Relative to most industrial processes, borax mining and refining is a “low-energy” process. Even with a conservative (high) estimate for fire retardants, embodied energy for cellulose insulation would be only about 750 Btu/lb. This figure is less than one-seventh the energy used to produce fiberglass, and one-30th that required for polystyrene (see table).

 

Energy Efficiency

In addition to the environmental benefits relating to resource use and embodied energy, cellulose insulation also has performance advantages over most other fiber insulation materials. Cellulose insulation has a higher R-value than standard fiberglass insulation, though high-density fiberglass can provide higher R-value than cellulose. With attic applications, loose-fill cellulose also blocks air convection within the insulation—a process that can significantly reduce the effective R-value of loose-fill fiberglass in very cold regions (see below). Settling, however, is more of a concern with loose-fill (non-stabilized) cellulose than with fiberglass insulation. In wall applications, wet-spray cellulose fills around wires and pipes, sealing the cavity more effectively than fiberglass batts, and settling does not occur. In fact, because of the very good air barrier provided by wet-spray cellulose, many installers suggest that a polyethylene vapor barrier is not required.

Unlike with fiberglass, the R-value of cellulose insulation does not increase as the density increases. Loose-fill cellulose in attics, at a typical density of about 1.5 lbs./ft3 insulates to between 3.6 and 3.8 per inch according to Dave Yarbrough at Oak Ridge National Laboratory. At higher densities, such as wet-spray wall applications (typically 2-3 lbs./ft3), the R-value is slightly lower: 3.5 to 3.6 per inch. With fiberglass, the R-value increases at higher densities up to about R-4 per inch.

In side-by-side tests conducted at the University of Colorado School of Architecture and Planning, two identical test buildings were built on insulated platforms. Cellulose insulation increased the air tightness by 74% over the uninsulated building, while the fiberglass insulation increased air tightness by 41% (neither building had a vapor barrier). The heating tests showed that the cellulose-insulated building used 26% less energy than the fiberglass-insulated building. Because these were short-term tests, it is not known whether settling of the loose-fill cellulose insulation over time would affect its energy performance.

 

Comparisons between loose-fill cellulose and loose-fill fiberglass attic insulation in very cold conditions have also been made both by the University of Illinois and by Oak Ridge National Laboratory. Both studies showed that at very cold temperatures loose-fill fiberglass loses up to 50% of its R-value, while loose-fill cellulose and fiberglass batt insulation do not. It is worth noting, however, that the extra heating costs from convection in loose-fill fiberglass in even an extreme North Dakota climate will only increase annual heating costs by about 2.4¢/ft2 of attic at an R-19 insulation level and 1.4¢/ft2 at an R-38 insulation level.

 

Health Concerns

Just how safe cellulose insulation is for installers and homeowners has been the subject of considerable controversy in the past few years. Some healthy house proponents argue that the chemicals found in the insulation and the cellulose fibers themselves are harmful and potentially even carcinogenic. Let’s take a look at these chemicals.

Cellulose insulation is typically about 20% fire-retardant chemicals by weight. The most commonly used fire retardants in cellulose insulation are boric acid, sodium borate, and ammonium sulfate. Informational materials published by Owens Corning Fiberglas claims that borates and boric acid are “known to cause reproductive disorders in rats. Medical authorities also warn that borates and boric acid may cause toxic poisoning in humans if absorbed through a cut or scrape. Ingesting as little as 1/8 ounce of these chemicals can be fatal to infants.” An article in the British Journal of Industrial Medicine (February 1993) by J. M. G. Davis goes into greater detail about health concerns:

“Boric acid itself is a toxic material and can be lethal to humans when ingested in gram quantities. It is not considered that the inhalation of cellulose insulation dust could approach this lethal toxicity but the heavily impregnated respirable cellulose dust will liberate the readily soluble boric acid in significant amounts in lung tissue. Symptoms of sublethal toxicity to boric acid include abdominal pain, liver, kidney, and lung dysfunction and severe exfoliative dermatitis.”

A front-page article in

Energy Design Update (June 1993), however, brings into question the validity of Davis’s article by noting that he is “under retainer to fiberglass and rockwool manufacturers and that in fact ‘one of those groups’ suggested he write the journal article.” A letter from Davis is quoted in the article as follows: “I would certainly emphasize that I do not feel that most cellulose fiber manufacturing or products present any hazard at all, if only because most will not liberate respirable fibers in significant amounts. Even in the most questionable case of shredded paper insulation materials, where the chemicals I listed [boron fire retardants] do occur, I fully acknowledge that there is no definite evidence that sufficient [amounts] can be inhaled to be harmful” (bracketed items from EDU article).

Concerns have also been raised about ink residues in cellulose insulation. There are two basic types of ink used in newspaper printing, according to Don Hensel, Environmental Manager at the Newspaper Association of America (NAA). Black inks have traditionally been a mixture of 60-80% petroleum-based mineral oil, 15-20% pure carbon black, and small amounts of other additives. In recent years, soy-based inks have gained in popularity. With these inks, oil made from soy beans replaces the mineral oil; the carbon black is still the same. The primary concern with inks has always been colored inks, which were traditionally made with toxic heavy metals such as cadmium and lead. According to Patricia Penza of the General Printing Ink Division of Sun Chemical, however, colored pigments weren’t used in the news industry until about ten years ago. By that time, she said, the health hazards of lead and other heavy metals were well known and NAA (then the American Newspaper Publishers Association) banned their use in newspaper inks.

Dr. John Comerford at the College of Agricultural Sciences at Penn State University has studied the safety of using shredded newspaper as animal bedding. He found no detectable levels of 16 different hydrocarbons in blood and liver samples. Of the metals cadmium, copper, lead, and mercury, only copper was found in measurable levels. Copper levels were “well below the toxic level” and higher levels were found in a control group of cattle that were bedded on sawdust. As for the newspaper bedding itself (shredded newspaper), cadmium, copper, and lead were found at levels less than 1100 the levels permitted in feed.

Insulation expert David Yarbrough of Oak Ridge National Laboratory dismisses most of the concern surrounding toxicity of cellulose. “I think that’s a major red herring,” he said. “The installer in an attic certainly is exposed to quite a bit of dust, …[but] as far as occupants are concerned, to me it’s a nonsense issue.” He noted that these health concerns were originally prompted by asbestos and that the concerns bled over into mineral fibers. The mineral insulation industry, “in a logical counter argument, said you ought to look at the cellulostic fibers and the chemicals and dust and all that’s associated with it,” added Yarbrough.

EBN’s recommendations on the health concerns raised with cellulose are as follows: 1) don’t eat it, 2) installers should always wear proper respiratory protection, and 3) as with other fiber insulation materials, it should be installed with a continuous air-tight barrier between the insulation and the living area (i.e., in most of the country, that means installation of polyethylene vapor barriers on walls and ceilings).

 

Fire Safety Concerns

Potential combustibility of cellulose insulation has long been an issue of concern, given the inherent combustibility of its primary raw material. As mentioned, various chemicals are added to provide fire-retardant properties. The biggest concern with these chemicals—all of which are readily water-soluble—is that they might leach out or somehow dissipate from the insulation over time. Concern has been particularly great with borates.

The North American Insulation Manufacturers Association (NAIMA), a trade association representing the fiberglass and mineral wool industries, has publicized the results of several reports showing that the fire resistance of cellulose insulation drops over time. Specifically, NAIMA cites a study by an association member of 24 loose-fill cellulose insulation samples from attics in six states that had been in place for at least two years. “Of the 19 samples tested for critical radiant flux [a value that influences the ability of flame to spread across insulation], 10 failed to meet the ASTM C 739 criterion.” Even more damaging is an ongoing study by the California Bureau of Home Furnishings and Thermal Insulation (CBHF) to measure the long-term performance of cellulose insulation relative to flammability. Over three years of testing, boric acid and borax levels were found to drop and the insulation samples “failed to meet the critical radiant flux requirements of ASTM C 739,” according to the NAIMA report.

The CBHF does not seem overly concerned about these results, however. In an October 1992 letter to a cellulose insulation manufacturer (provided to EBN by CIMA), the chief of the CBHF said that “…the long term aging studies show the samples maintain their ability to pass the smoldering test normally administered on new materials. We consider the smoldering test a much more important test than the critical radiant panel in predicting in-field fire performance…. We have not received a significant number of reports from California fire departments indicating that insulation materials constitute a fire hazard or major consequence.”

Several studies by researchers at Tennessee Technological University (TTU) and Allied Signal Corporation provide evidence that the fire-retardant chemicals do not disappear from cellulose insulation except at much higher temperatures than would commonly be found in attics. The most thorough and widely quoted study was done by David Yarbrough of ORNL and N. Chiou of TTU and published in

Energy and Buildings in 1990. Enough vibration to simulate 672 years of use in an attic was found to cause no measurable settling of boric acid or borax in test samples. As for evaporation (sublimation) of boric acid from cellulose, the study found that at very high temperatures (90°C or 194°F) and 100% relative humidity, the loss of boric acid was significant, but the loss was negligible when the temperature is lower 70°C (158°F), even at 100% humidity and air exchange rates of 2.0 attic changes per hour. “It appears that it would take 300 years or more at 70°C, 100% relative humidity, and air exchange rates from 1.0 to 2.0 attic volumes per hour to lose enough boric acid to significantly affect the combustion tests,” according to the article’s authors. Separate studies of ammonium sulfate by David Yarbrough and Allied Signal Corporation reached similar conclusions: that loss was not significant except at very high temperatures.

EBN considers the potential loss of fire-retardant chemicals to be the most significant concern relating to cellulose insulation. Further research on this concern is clearly needed, but the apparent lack of building fires in which cellulose insulation has been implicated gives us confidence that cellulose insulation is safe enough for use.

 

Disposal of Cellulose Insulation

When the useful life of any insulation material comes to an end—i.e., when the building is demolished or the insulation removed during renovation—what happens to it? Cellulose is not readily reusable as an insulation material. Even if it weren’t so messy, given the concerns about fire-retardant chemicals with new cellulose insulation, the acceptability of fire retardants in old cellulose should be highly suspect. In most cases, the material is either landfilled or incinerated. If landfilling is the disposal method, cellulose insulation does pretty well because of its inherent biodegradability. As the cellulose decomposes, however, the borate and ammonium sulfate fire-retardant chemicals will remain. In older landfills, these water-soluble chemicals, dissolved in rainwater (leachate), can permeate through the underlying soils. According to a Material Safety Data Sheet from U.S. Borax, “although boron is an essential micronutrient for healthy growth of plants, it can be harmful to boron-sensitive plants in higher levels,” and it is toxic to some fish at levels of 1 mg per liter. Overall, the toxicity of the borates in cellulose insulation is low enough that cellulose insulation is not considered a hazardous material even in California, which has the nation’s most stringent standards. “You can dispose of it in any landfill,” according to Jerry Pepper, manager of environmental affairs at U.S. Borax.

 

Corrosion Concerns

If ammonium sulfate gets wet or thermally decomposes, it can produce sulfuric acid, which is corrosive to metals. There have been anecdotal reports of copper pipes and steel truss fasteners in attics corroding when in contact with cellulose insulation that has gotten wet. With the rising popularity of wet-spray cellulose for wall applications, the issue of corrosivity is particularly significant. Many wet-spray cellulose installers specify material treated only with boric acid and borax to eliminate concern about corrosion. According to David Yarbrough, however, all cellulose insulation must pass corrosivity tests, and if properly installed, any commercially available cellulose should be all right. To improve resistance to corrosion, some manufacturers may add corrosion inhibitors.

 

Does Wet-Spray Cellulose Insulation Dry Out?

With wet-spray cellulose insulation concern is often expressed that moisture from the insulation might remain trapped in the wall cavity and result in rotting or mildew growth. The concern is greatest in situations where there is an effective vapor barrier on both sides of the wall cavity—for example, when foam sheathing or plywood is used on the exterior and a polyethylene vapor barrier is used on the interior. There have been a number of horror stories, such as a public housing project in New England where in one building, even after 112 years, the insulation moisture content was found to be 30-60% (Energy Design Update, July 1989). In this case, it appears that the insulation was installed very wet (up to 200% moisture on a dry-weight basis—five to six gallons of water per 30-pound bag), and the wall system impeded drying (interior polyethylene vapor barrier and meticulously installed extruded polystyrene on the exterior). An experimental study of different wall systems by the Canada Mortgage and Housing Corporation in Newfoundland (1986 and 1987) found that even after two years, wet-spray cellulose had not dried and the moisture level in studs was about 60% (Energy Design Update, November 1987).

A study in Calgary, Alberta, on the other hand (where the climate is drier), showed that wet-spray cellulose dries out quite well. One wall of a test house was configured to test for the effect of poly vapor barriers and the tightness of the exterior sheathing. Even the wall section with a poly vapor barrier on the interior and well-sealed plywood sheathing on the exterior dried to acceptably low moisture levels within 120 days (Energy Design Update, October 1989).

Clearly there is cause for concern in humid climates. Wet-spray cellulose should only be used in situations where adequate provision has been made for drying of the insulation. Joe Lstiburek, of Building Science Corporation, who co-authored the

Moisture Control Handbook for the U.S. Department of Energy, says that when using wet-spray cellulose the wall must have adequate drying potential. In northern climates, it must be able to dry to the exterior. That means a moisture-permeable exterior sheathing such as one-by lumber, asphalt-impregnated fiberboard, or an exterior gypsum board. In warm climates where there will be central air conditioners operating during the summer, the wall can be designed to dry to the interior by leaving out the interior vapor barrier, says Lstiburek.

If vapor retarders are to be used on both sides of wet-spray insulation, provision needs to be made for the insulation to dry out before the wall system is closed in. Depending on the climate conditions, low-water-content wet-spray cellulose insulation can dry at a rate of up to about one inch of depth per day, according to Ivan Sandau of American Environmental Products.

Along with allowing wet-spray insulation to dry, keeping it dry is also very important. Cellulose can absorb moisture. If soaked, it can compress. Even if only moistened, its R-value will drop, reducing energy performance, and the resultant humidity can permit mold growth or rotting of wood framing members. Proper detailing to prevent migration of water or water vapor into the insulation—from either the inside or outside—should be followed.

 

A Boost From

Louisiana-Pacific

Cellulose insulation is receiving a big image boost from Louisiana-Pacific on two accounts. First, L-P is the first company to market cellulose insulation nationally; its Nature Guard™ product is produced at four plants around the country and actively promoted through advertising campaigns and at trade shows. Second, at the end of July, L-P launched a program to guarantee low heating bills for homes insulated with their cellulose. Under the Snug Home program, a home must be tested for air tightness, and the leakage ratio must be between 2 and 3 (leakage ratio is defined as the Effective Leakage Area, divided by the square footage of the building envelope, divided by 100). If the home meets the air tightness requirement, L-P reviews the plans and determines the expected heating load, adds in a comfort margin, and provides a written warranty listing the maximum yearly heating costs for a period of three years. L-P will pay any difference in heating cost. While this program only covers Nature Guard, publicity about the program will increase awareness of cellulose insulation across the board, helping out all producers.

 

The Bottom Line

After thorough review, we at EBN have concluded that properly installed cellulose insulation is acceptable from a health standpoint. We found no significant risk of indoor air quality problems, combustion, or moisture damage if appropriate installation procedures are followed. The most significant concern—apparent loss of certain fire-retardant properties—calls for additional research but does not appear so significant as to suggest a moratorium on use. Given its environmental advantages over most other insulation materials (low energy production, high recycled material content, and biodegradability), EBN believes that cellulose insulation should be a preferred insulation material for environmentally concerned builders and designers. This is not to say that cellulose is the perfect insulation material; it is not. Care must be taken in its use to ensure proper performance and a long, safe operating life. A checklist for cellulose installation follows.

 

Alex Wilson

For more information:

Advanced Fiber Technology

4710-L Interstate Dr.

Cincinnati, OH 45246

513/860-4446

American Forest and Paper Association

1250 Connecticut Ave., N.W., Second Floor

Washington, DC 20036

202/463‑2420

Cellulose Insulation Manufacturers Association

136 S. Keowee St.

Dayton, OH 45402

513/222-2462

Newspaper Association of America\

11600 Sunrise Valley Dr.

Reston, VA 22091

703/648-1000

North American Insulation Manufacturers Association

44 Canal Center Plaza, Suite 301

Alexandria, VA 22314

703/684-0084

Therm-O-Comfort Co., Ltd.

85 Forest St.

Aylmer, Ontario N5H 1A5

519/773-8498

U.S. Borax Inc.

26877 Tourney Rd.

Valencia, CA 91355

805/287-5400

805/287-5455 (fax)

 
 

 

Published September 1, 1993

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Embodied Energy--Just What Is It and Why Do We Care?

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Embodied Energy--Just What Is It and Why Do We Care?

Almost all the attention paid to energy conservation in buildings has focused on reducing their operating energy, but embodied energy can add up to many years’ worth of operating energy in an efficient building.

Comparing Embodied Energy with Operating Energy

Estimates provided by Professor Ray Cole of the University of British Columbia’s School of Architecture. House modeled is a 3,750 ft2 ranch. Energy-efficient version assumes ceiling R-values raised from R-24 to R-42, 2x4 walls replaced with 2x6 walls, additional glazing on south elevation, and added thermal mass to temper indoor temperatures.

Almost all the attention paid to energy conservation in buildings has focused on reducing their operating energy. Given the energy hogs that many buildings were (and are), this focus is appropriate. As builders and architects succeed in making their buildings more efficient, however, the energy used to build buildings starts to look significant. This embodied energy can add up to many years’ worth of operating energy in an efficient building (see table). While taking steps to reduce operating energy is clearly the first priority, it makes sense to look for options that minimize the initial energy investment—the embodied energy—as well.

Embodied energy is a term coined to express the energy consumed in the production of a particular product or material. Some scientists use the term energy intensity to describe the embodied energy per unit (pound, kilogram, cubic foot, cubic meter, etc.) of a material. The energy used to produce the materials, together with the energy needed to assemble them, gives the embodied energy of a building component, or of a whole building. Energy intensity figures for materials, or embodied energy values for components, can provide useful information for comparing different building products, or choosing from among several different materials.

Quantifying the energy intensity of materials is not an exact science. Manufacturing procedures can vary greatly from one site to the next, or by season. Every effort to measure energy inputs requires many assumptions, and these often vary greatly among researchers. Production generally begins with one or more raw materials that have to be mined or harvested, transported to factories, and processed into usable products. The finished products then have to be transported to the building site. For some materials the processing and manufacturing stage can have several steps, with initial processing at one site, further transportation and secondary processing at another site, and so on. The flow of materials and energy for products made up of many different components (such as a window, for example) can be quite complicated.

Some researchers have worked to clarify the assumptions involved by assigning different levels or orders of energy use based on how directly the activity is connected to the manufacturing process:

  • First order energy: fuel use for mining, transporting raw material, energy use at manufacturing facility.
  • Second order: energy used to produce the equipment and machinery that does the work, and to transport workers to and from the site.
  • Third order: general support services and social services for workers, second order energy for machinery, equipment and infrastructure.

While some embodied energy studies have attempted to include second and third order energy values in their data, most do not. These secondary energy values can be quite large taken as a whole, but once their contribution to the energy picture is spread over the full amount of material it becomes much less significant. The amount of diesel fuel burned by an excavator in a gravel quarry (first order energy), will over its useful life dwarf the energy invested in making the machine (second order energy). Other second order contributions, such as the transportation of workers, can be more significant because they occur on an ongoing basis along with the actual mining or manufacturing. The unknowns and variability from one site to the next make these figures almost impossible to quantify, however. As a result, many researchers choose to assume that such factors will be comparable from one industry to the next, and as such can be left out without compromising the relative embodied energy assessment.

The most important and difficult part of relative embodied energy assessments is making sure that all the assumptions and boundaries of the study are the same for all materials involved. When comparative work is done by one researcher or group of researchers the parameters can be established and shared. To date, however, most embodied energy research projects have focused on one particular field or industry, and comparing the results of different projects is tricky at best.

Industry associations representing wood products, plastics, and concrete have all commissioned studies in the hopes of showing the energy advantages of their materials. As might be expected, the conclusions released from those studies that have been completed vary tremendously. A study commissioned by the Society for the Plastics Industry (SPI) and performed in 1990 by Franklin Associates of Kansas City, Missouri, provides embodied energy values for cement that are three to five times higher than those suggested by independent Canadian studies from the mid-eighties. Research done by Scientific Certification Systems of Oakland, California, for the Western Wood Products Association has not been released to the public, while the concrete studies are just beginning. Until several different associations commission studies from the same researcher, using the same methods, it is impossible to compare the results reliably.

Fortunately, there is some independent research to work from, including efforts to incorporate embodied energy into the larger environmental picture. While much of the current work is from Canada and Europe, it is American researchers in the mid-1970s who laid the groundwork in terms of energy analyses of industrial processes. The work of Harry Brown (on industrial processes in general), and Richard Stein and Diane Serber (on energy use in building construction), provided the raw data which is still used as a basis for many studies. By comparing this research with industry-funded studies it is possible to make some reasonable comparisons of materials, at least those that have been studied. As more material becomes available, EBN will keep you updated on the results of those comparisons.

References:

Brown, Harry, et al. 1985 Energy Analysis of 108 Industrial Processes. Washington, D.C.: U.S. Department of Energy.

Cole, Raymond J. and David Rousseau (both of the Environmental Research Group, School of Architecture, University of British Columbia, Vancouver, BC, Canada, V6T 1W5). “Environmental Auditing for Building Construction: Energy and Air Pollution Indices for Building Materials.” Building and Environment Vol. 27, No. 1, pp. 23-30, 1992.

Corrim Panel II. “Wood for Structural and Architectural Purposes,” Wood and Fiber Vol. 8, No. 1 Spring, 1976.

Food and Agriculture Organization of the United Nations. Energy Conservation in the Mechanical Forest Industries. Rome, Italy. 1990.

Franklin Associates, Ltd. 1991. Comparative Energy Evaluation of Plastic Products and Their Alternatives for the Building and Construction and Transportation Industries. Prairie Village, Kansas. Report prepared for The Society of the Plastics Industry.

Hannon, Bruce et al. “Energy and Labor in the Construction Sector.” Science Vol. 202, 24 November 1978, pp 837-847.

Stein, R.G. and Diane Serber. 1979. “Energy Required for Building Construction.” Chapter 10 of Energy Conservation Through Building Design. D. Watson. New York, McGraw Hill.

Other Contacts:

Scientific Certification Systems, 1611 Telegraph Ave., Suite 1111, Oakland, CA 94612; 510/832-1415.

Canadian Mortgage and Housing Corporation, 682 Montreal Rd., Ottawa, ON K1A 0P7, Canada; 613/748-2367. CMHC is developing an extensive database program, called Optimize, to assess the environmental impact of houses. Optimize runs on Excel and requires an IBM or compatible PC with high-speed processor. It is currently in final testing stages.

 

Published May 1, 1993

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