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LCA results & interpretation Pyrocrete Series

Life cycle assessment

Scope and summary

  • Cradle to gate
  • Cradle to gate with options
  • Cradle to grave

Product description

Carboline’s Pyrocrete products are Portland cement-based, cementitious fireproofing that is mixed with clean, potable water onsite before application. The products are spray applied to the substrate using either piston or rotor stator or squeeze type pumps. Pyrocrete products provide fire protection for structural steel and can also be used to upgrade the fire resistance of existing concrete. They are high density cementitious fireproofing products designed for the fire protection of exterior and interior structural steel.


Carboline’s Pyrocrete series includes four products: Pyrocrete 239, Pyrocrete 241, Pyrocrete 341, and Pyrocrete 40. The impacts are presented for these four products covered in this report. The kraft paper bag packaging weight for these products as delivered are 1.66 kg, 1.54 kg, 0.56kg, and 1.66 kg, respectively.

Declared unit

The declared unit is 1,000 kg of product. The results in this report are expressed in terms of potential impacts per 1,000 kg of product from cradle to gate.

Manufacturing data

Time coverage: The data covers annual manufacturing data for the 2021 calendar year from Carboline’s manufacturing plant in Lake Charles, Louisiana. This period of time was chosen in order to capture a representative picture of businesses activities at Carboline.


Geographical coverage: The geographical coverage for this study is based on United States system boundaries for all processes and products.

What’s causing the greatest impacts

All life cycle stages

Activities during the supply of raw materials (A1) are responsible for much of the impacts in each impact category. The next highest impact contributor is manufacturing (A3) in most of the impact categories.

Raw material supply

Raw material supply (A1) includes raw material extraction and upstream processing. This module dominates the results for most of the impact categories. For example, A1 accounts for over 65% of the impact of global warming, smog, and acidification. It also contributes to over 50% of ozone depletion and eutrophication.

Transportation

Average transportation distances and modes of transport are included for the transportation of raw materials to the production facility. Typical vehicles used include trucks and ships. Transportation of raw materials is a relatively small contributor to all product life cycle impacts.

Manufacturing

Manufacturing (A3) is the second highest contributor to eight impact categories for Pyrocrete 239, seven impact categories for Pyrocrete 241, five impact categories for Pyrocrete 341, and six impact categories for Pyrocrete 40.

System boundary

The figure below illustrates the system boundary for the LCA, defining which life cycle stages are included and which are excluded. For this report, the system boundary is cradle-to-gate, which includes modules A1, A2, and A3: raw materials extraction, processing, transportation, and manufacturing/final assembly for both the product and its associated packaging. All other life cycle stages are excluded from the analysis.

Sensitivity analysis

Sensitivity analyses were performed to check the robustness of the results where the highest potential environmental impacts are occurring. As the bulk of impacts are attributed to raw materials acquisition and processing, the mass of specified raw materials was changed by +/-20%. These raw materials were chosen based on a combination of relatively higher contribution to the results.


Global warming potential was evaluated for sensitivity since Carboline is interested in the potential CO2-equivalent emissions of its products. The range of change in total life cycle impacts was in a +/-6-12% change.

How we're making it greener

Carboline is committed to finding new and efficient alternatives in manufacturing, raw material sourcing, and logistics to improve sustainability efforts. One of Carboline’s most impactful contributions is the creation of the SLOB Program (slow moving and obsolete inventory). To reduce hazardous waste generation, the SLOB Program was designed to provide optics to Carboline’s Inventory Analytics Team to review inventory close to expiration. Preventative measures are taken to rework inventory or sell this material at a discounted rate, with the ultimate goal of preventing little to zero waste of unused material. As an RPM company, Carboline is dedicated to working towards reaching the goals that have been set through RPM’s Building a Better World Program. These goals include reducing energy consumption, landfill contributions, and water reuse/conservation opportunities.

See how we make it greener

LCA results

Life cycle stage Production stage Production stage Production stage

Information modules: Included (X) |
Excluded* (MND)

*Modules A4, A5, B, C, and D are excluded.

 A1 Raw material supply A2 Transport A3 Manufacturing

SM Single Score

Learn about SM Single Score results
Impacts per 1,000kg of coating 1.41E+02 mPts 5.58E+00 mPts 9.25E+00 mPts
Materials or processes contributing >20% to total impacts in each life cycle stage Energy used for raw material extraction (electricity and fuels). Truck and trailer transportation (fuel consumption). Energy and electricity consumed for coating production.

Pyrocrete 239: TRACI v2.1 results per declared unit

Life cycle stage A1 Raw material supply A2 Transport A3 Manufacturing

Ecological damage

Impact category Unit
Acidification kg SO2 eq Kilograms of Sulfur Dioxide equivalent
Acidification processes increase the acidity of water and soil systems and causes damage to lakes, streams, rivers and various plants and animals as well as building materials, paints and other human-built structures. 		2.10E+00 1.00E-01 4.73E-01
Eutrophication kg N eqKilograms of Nitrogen equivalent
Eutrophication is the enrichment of an aquatic ecosystem with nutrients (nitrates and phosphates) that accelerate biological productivity (growth of algae and weeds) and an undesirable accumulation of algal biomass which impacts industry, agriculture, drinking, fishing and recreation and causes death of fish and shellfish, toxicity to humans, marine mammals and livestock, and reduces biodiversity.		 3.36E-01 1.95E-02 1.52E-01
Global warming kg CO2 eqKilograms of Carbon Dioxide equivalent
Global warming is an average increase in the temperature of the atmosphere near the Earth’s surface and in the troposphere, which can contribute to change in global climate patterns and is caused by the increase of the sources of greenhouse gases and decrease of the sinks due to deforestation and land use. Global warming - 100 a refers to the reporting period of 100 years. GW leads to problems in human health, agriculture, forest, water source and damage to species and biodiversity as well as coastal areas.		 6.41E+02 5.33E+01 1.78E+02
Ozone depletion kg CFC-11 eq Kilograms of Trichlorofluoromethane equivalent
Ozone depletion is the reduction of ozone in the stratosphere caused by the release of ozone depleting chemicals. Ozone depletion can increases ultraviolet B radiation to the earth which can adversely affect human health (skin cancer and cataracts and immune-system suppression) and other system (marine life, agricultural crops, and other vegetation) and causes damage to human-built materials. 		2.85E-05 1.27E-05 7.59E-06

Human health damage

Impact category Unit
Carcinogenics CTUh Comparative Toxic Units of Human cancerous toxicity
Carcinogens have the potential to form cancers in humans. 		1.89E-05 4.89E-08 1.05E-06
Non-carcinogenics CTUh Comparative Toxic Units of Human non-cancerous toxicity
Non-Carcinogens have the potential to causes non-cancerous adverse impacts to human health. 		6.01E-05 7.45E-06 8.85E-06
Respiratory effects kg PM2.5 eqKilograms of Particulate Matter equivalent which are smaller than or equal to 2.5 micrometers in diameter
Particulate matter concentrations have a strong influence on chronic and acute respiratory symptoms and mortality rates.		 2.80E-01 1.91E-02 6.86E-02
Smog kg O3 eqKilograms of Ozone equivalent
Smog formation (photochemical oxidant formation) is the formation of ozone molecules in the troposphere by complex chemical reactions which are influenced by ambient concentrations of oxides of nitrogen (NOx), volatile organic compounds (VOCs), the mix of organic compounds (OCs), temperature, sunlight and convective flows. Ozone concentrations in the Earth’s atmosphere above the natural trace amounts lead to detrimental impacts on human health and ecosystems.		 3.73E+01 1.32E+00 6.97E+00

Additional environmental information

Impact category Unit
Fossil fuel depletion MJ surplus Mega Joule, lower heating value
Fossil fuel depletion is the surplus energy to extract minerals and fossil fuels. 		3.38E+02 1.13E+02 2.44E+02
Ecotoxicity CTUe Comparative Toxic Units of Ecotoxicity
Ecotoxicity causes negative impacts to ecological receptors and, indirectly, to human receptors through the impacts to the ecosystem.		 4.10E+02 1.51E+02 2.14E+02

See the additional content required by the ASTM PCR for spray-applied fire-resistive materials on page 4 of the Transparency Report PDF.

Pyrocrete 241: TRACI v2.1 results per declared unit

Life cycle stage A1 Raw material supply A2 Transport A3 Manufacturing

Ecological damage

Impact category Unit
Acidification kg SO2 eq Kilograms of Sulfur Dioxide equivalent
Acidification processes increase the acidity of water and soil systems and causes damage to lakes, streams, rivers and various plants and animals as well as building materials, paints and other human-built structures. 		2.19E+00 1.38E-01 4.52E-01
Eutrophication kg N eqKilograms of Nitrogen equivalent
Eutrophication is the enrichment of an aquatic ecosystem with nutrients (nitrates and phosphates) that accelerate biological productivity (growth of algae and weeds) and an undesirable accumulation of algal biomass which impacts industry, agriculture, drinking, fishing and recreation and causes death of fish and shellfish, toxicity to humans, marine mammals and livestock, and reduces biodiversity.		 1.88E-01 2.89E-02 1.59E-01
Global warming kg CO2 eqKilograms of Carbon Dioxide equivalent
Global warming is an average increase in the temperature of the atmosphere near the Earth’s surface and in the troposphere, which can contribute to change in global climate patterns and is caused by the increase of the sources of greenhouse gases and decrease of the sinks due to deforestation and land use. Global warming - 100 a refers to the reporting period of 100 years. GW leads to problems in human health, agriculture, forest, water source and damage to species and biodiversity as well as coastal areas.		 5.78E+02 7.97E+01 1.94E+02
Ozone depletion kg CFC-11 eq Kilograms of Trichlorofluoromethane equivalent
Ozone depletion is the reduction of ozone in the stratosphere caused by the release of ozone depleting chemicals. Ozone depletion can increases ultraviolet B radiation to the earth which can adversely affect human health (skin cancer and cataracts and immune-system suppression) and other system (marine life, agricultural crops, and other vegetation) and causes damage to human-built materials. 		3.31E-05 1.90E-05 7.33E-06

Human health damage

Impact category Unit
Carcinogenics CTUh Comparative Toxic Units of Human cancerous toxicity
Carcinogens have the potential to form cancers in humans. 		8.32E-05 7.31E-08 1.07E-06
Non-carcinogenics CTUh Comparative Toxic Units of Human non-cancerous toxicity
Non-Carcinogens have the potential to causes non-cancerous adverse impacts to human health. 		1.61E-04 1.12E-05 8.48E-06
Respiratory effects kg PM2.5 eqKilograms of Particulate Matter equivalent which are smaller than or equal to 2.5 micrometers in diameter
Particulate matter concentrations have a strong influence on chronic and acute respiratory symptoms and mortality rates.		 3.09E-01 2.79E-02 6.46E-02
Smog kg O3 eqKilograms of Ozone equivalent
Smog formation (photochemical oxidant formation) is the formation of ozone molecules in the troposphere by complex chemical reactions which are influenced by ambient concentrations of oxides of nitrogen (NOx), volatile organic compounds (VOCs), the mix of organic compounds (OCs), temperature, sunlight and convective flows. Ozone concentrations in the Earth’s atmosphere above the natural trace amounts lead to detrimental impacts on human health and ecosystems.		 3.18E+01 1.78E+00 6.61E+00

Additional environmental information

Impact category Unit
Fossil fuel depletion MJ surplus Mega Joule, lower heating value
Fossil fuel depletion is the surplus energy to extract minerals and fossil fuels. 		3.39E+02 1.69E+02 2.41E+02
Ecotoxicity CTUe Comparative Toxic Units of Ecotoxicity
Ecotoxicity causes negative impacts to ecological receptors and, indirectly, to human receptors through the impacts to the ecosystem.		 1.12E+03 2.26E+02 2.05E+02

See the additional content required by the ASTM PCR for spray-applied fire-resistive materials on page 4 of the Transparency Report PDF.

Pyrocrete 341: TRACI v2.1 results per declared unit

Life cycle stage A1 Raw material supply A2 Transport A3 Manufacturing

Ecological damage

Impact category Unit
Acidification kg SO2 eq Kilograms of Sulfur Dioxide equivalent
Acidification processes increase the acidity of water and soil systems and causes damage to lakes, streams, rivers and various plants and animals as well as building materials, paints and other human-built structures. 		2.91E+00 2.26E-01 2.70E-01
Eutrophication kg N eqKilograms of Nitrogen equivalent
Eutrophication is the enrichment of an aquatic ecosystem with nutrients (nitrates and phosphates) that accelerate biological productivity (growth of algae and weeds) and an undesirable accumulation of algal biomass which impacts industry, agriculture, drinking, fishing and recreation and causes death of fish and shellfish, toxicity to humans, marine mammals and livestock, and reduces biodiversity.		 3.36E-01 4.39E-02 1.17E-01
Global warming kg CO2 eqKilograms of Carbon Dioxide equivalent
Global warming is an average increase in the temperature of the atmosphere near the Earth’s surface and in the troposphere, which can contribute to change in global climate patterns and is caused by the increase of the sources of greenhouse gases and decrease of the sinks due to deforestation and land use. Global warming - 100 a refers to the reporting period of 100 years. GW leads to problems in human health, agriculture, forest, water source and damage to species and biodiversity as well as coastal areas.		 9.57E+02 1.20E+02 1.98E+02
Ozone depletion kg CFC-11 eq Kilograms of Trichlorofluoromethane equivalent
Ozone depletion is the reduction of ozone in the stratosphere caused by the release of ozone depleting chemicals. Ozone depletion can increases ultraviolet B radiation to the earth which can adversely affect human health (skin cancer and cataracts and immune-system suppression) and other system (marine life, agricultural crops, and other vegetation) and causes damage to human-built materials. 		7.00E-05 2.85E-05 5.01E-06

Human health damage

Impact category Unit
Carcinogenics CTUh Comparative Toxic Units of Human cancerous toxicity
Carcinogens have the potential to form cancers in humans. 		7.33E-05 1.10E-07 6.96E-07
Non-carcinogenics CTUh Comparative Toxic Units of Human non-cancerous toxicity
Non-Carcinogens have the potential to causes non-cancerous adverse impacts to human health. 		1.65E-04 1.67E-05 4.51E-06
Respiratory effects kg PM2.5 eqKilograms of Particulate Matter equivalent which are smaller than or equal to 2.5 micrometers in diameter
Particulate matter concentrations have a strong influence on chronic and acute respiratory symptoms and mortality rates.		 2.58E+00 4.28E-02 3.02E-02
Smog kg O3 eqKilograms of Ozone equivalent
Smog formation (photochemical oxidant formation) is the formation of ozone molecules in the troposphere by complex chemical reactions which are influenced by ambient concentrations of oxides of nitrogen (NOx), volatile organic compounds (VOCs), the mix of organic compounds (OCs), temperature, sunlight and convective flows. Ozone concentrations in the Earth’s atmosphere above the natural trace amounts lead to detrimental impacts on human health and ecosystems.		 4.18E+01 2.99E+00 3.43E+00

Additional environmental information

Impact category Unit
Fossil fuel depletion MJ surplus Mega Joule, lower heating value
Fossil fuel depletion is the surplus energy to extract minerals and fossil fuels. 		1.31E+03 2.53E+02 2.13E+02
Ecotoxicity CTUe Comparative Toxic Units of Ecotoxicity
Ecotoxicity causes negative impacts to ecological receptors and, indirectly, to human receptors through the impacts to the ecosystem.		 1.16E+03 3.38E+02 9.94E+01

See the additional content required by the ASTM PCR for spray-applied fire-resistive materials on page 4 of the Transparency Report PDF.

Pyrocrete 40: TRACI v2.1 results per declared unit

Life cycle stage A1 Raw material supply A2 Transport A3 Manufacturing

Ecological damage

Impact category Unit
Acidification kg SO2 eq Kilograms of Sulfur Dioxide equivalent
Acidification processes increase the acidity of water and soil systems and causes damage to lakes, streams, rivers and various plants and animals as well as building materials, paints and other human-built structures. 		2.13E+00 1.65E-01 4.75E-01
Eutrophication kg N eqKilograms of Nitrogen equivalent
Eutrophication is the enrichment of an aquatic ecosystem with nutrients (nitrates and phosphates) that accelerate biological productivity (growth of algae and weeds) and an undesirable accumulation of algal biomass which impacts industry, agriculture, drinking, fishing and recreation and causes death of fish and shellfish, toxicity to humans, marine mammals and livestock, and reduces biodiversity.		 2.82E-01 3.31E-02 1.66E-01
Global warming kg CO2 eqKilograms of Carbon Dioxide equivalent
Global warming is an average increase in the temperature of the atmosphere near the Earth’s surface and in the troposphere, which can contribute to change in global climate patterns and is caused by the increase of the sources of greenhouse gases and decrease of the sinks due to deforestation and land use. Global warming - 100 a refers to the reporting period of 100 years. GW leads to problems in human health, agriculture, forest, water source and damage to species and biodiversity as well as coastal areas.		 6.60E+02 9.07E+01 1.96E+02
Ozone depletion kg CFC-11 eq Kilograms of Trichlorofluoromethane equivalent
Ozone depletion is the reduction of ozone in the stratosphere caused by the release of ozone depleting chemicals. Ozone depletion can increases ultraviolet B radiation to the earth which can adversely affect human health (skin cancer and cataracts and immune-system suppression) and other system (marine life, agricultural crops, and other vegetation) and causes damage to human-built materials. 		2.98E-05 2.16E-05 7.61E-06

Human health damage

Impact category Unit
Carcinogenics CTUh Comparative Toxic Units of Human cancerous toxicity
Carcinogens have the potential to form cancers in humans. 		4.95E-05 8.31E-08 1.12E-06
Non-carcinogenics CTUh Comparative Toxic Units of Human non-cancerous toxicity
Non-Carcinogens have the potential to causes non-cancerous adverse impacts to human health. 		6.92E-05 1.27E-05 8.97E-06
Respiratory effects kg PM2.5 eqKilograms of Particulate Matter equivalent which are smaller than or equal to 2.5 micrometers in diameter
Particulate matter concentrations have a strong influence on chronic and acute respiratory symptoms and mortality rates.		 3.13E-01 3.21E-02 6.88E-02
Smog kg O3 eqKilograms of Ozone equivalent
Smog formation (photochemical oxidant formation) is the formation of ozone molecules in the troposphere by complex chemical reactions which are influenced by ambient concentrations of oxides of nitrogen (NOx), volatile organic compounds (VOCs), the mix of organic compounds (OCs), temperature, sunlight and convective flows. Ozone concentrations in the Earth’s atmosphere above the natural trace amounts lead to detrimental impacts on human health and ecosystems.		 3.39E+01 2.15E+00 7.00E+00

Additional environmental information

Impact category Unit
Fossil fuel depletion MJ surplus Mega Joule, lower heating value
Fossil fuel depletion is the surplus energy to extract minerals and fossil fuels. 		4.79E+02 1.92E+02 2.44E+02
Ecotoxicity CTUe Comparative Toxic Units of Ecotoxicity
Ecotoxicity causes negative impacts to ecological receptors and, indirectly, to human receptors through the impacts to the ecosystem.		 7.01E+02 2.57E+02 2.19E+02

See the additional content required by the ASTM PCR for spray-applied fire-resistive materials on page 4 of the Transparency Report PDF.

References

LCA Background Report

Carboline Spray-Applied Fire-Resistive Materials LCA Background Report (public version), Carboline 2022; SimaPro Analyst 9.4; Ecoinvent 3.4 and US ecoinvent (US-EI 2.2) database; TRACI 2.1

PCR for Spray-applied Fire-Resistive Materials (SFRM)

Valid through Feb. 29, 2023. PCR review conducted by Thomas P. Gloria (Industrial Ecology Consultants), Ph. D; Jeffrey E. Gould (FM Approvals); Karl D. Houser, (Intertek Building and Construction).

ISO 14025, “Sustainability in buildings and civil engineering works -- Core rules for environmental product declarations of construction products and services”

Download PDF SM Transparency Report, which includes the additional EPD content required by the ASTM PCR.

SM Transparency Reports (TR) are ISO 14025 Type III environmental declarations (EPD) that enable purchasers and users to compare the potential environmental performance of products on a life cycle basis. Environmental declarations from different programs (using different PCR) may not be comparable. In order to support comparative assertions, this EPD meets all comparability requirements stated in ISO 14025:2006. However, differences in certain assumptions, data quality, and variability between LCA data sets may still exist. As such, caution should be exercised when evaluating EPDs from different manufacturers, as the EPD results may not be entirely comparable. Any EPD comparison must be carried out at the building level per ISO 21930 guidelines. The results of this EPD reflect an average performance by the product and its actual impacts may vary on a case-to-case basis.

Rating systems

The intent is to reward project teams for selecting products from manufacturers who have verified life-cycle environmental performance.

LEED BD+C: New Construction | v4 - LEED v4

Building product disclosure and optimization

Environmental product declarations

  • Industry-wide (generic) EPD ½product

  • Product-specific Type III EPD 1 product

LEED BD+C: New Construction | v4.1 - LEED v4.1

Building product disclosure and optimization

Environmental product declarations

  • Industry-wide (generic) EPD 1 product

  • Product-specific Type III EPD 1.5 product

Green Globes for New Construction and Sustainable Interiors

Materials and resources

  • NC 3.5.1.2 Path B: Prescriptive Path for Building Core and Shell

  • NC 3.5.2.2 and SI 4.1.2 Path B: Prescriptive Path for Interior Fit-outs

Collaborative for High Performance Schools National Criteria

MW C5.1 – Environmental Product Declarations

  • Third-party certified type III EPD 2 points

BREEAM New Construction 2018

Mat 02 - Environmental impacts from construction products

Environmental Product Declarations (EPD)

  • Industry-average EPD .5 points

  • Product-specific EPD 1 point

  • Multi-product specific EPD .75 points

  • Verification LCA
  • 3rd-party reviewed
  • Transparency Report (EPD)
  • 3rd-party verified

The declaration is intended for use in Business-to-Consumer (B-to-C) communication.

Validity: 20230213 – 20280212

Decl #: CAR-20230213-004

This environmental product declaration (EPD) was externally verified, according to ASTM PCR for Spray-applied Fire Resistive Materials, and ISO 14025:2006, by Jack Geibig, President, Ecoform.

Ecoform, LLC
11903 Black Road,
Knoxville, TN 37932
www.ecoform.com

(865) 850-1883

SUMMARY

Reference PCR

ASTM PCR for Spray-applied Fire Resistive Materials

Regions; system boundaries
North America; Cradle to gate

Declared unit / reference service life:
1,000 kg of product

LCIA methodology: TRACI 2.1

LCA software; LCI database
SimaPro Developer 9.4
EcoInvent 3.8, US-EI 2.2, and ELCD databases.

LCA conducted by: Sustainable Minds

Public LCA:
Life Cycle Assessment of Carboline Spray-Applied Fire-Resistive Materials

©2026 | The SM Transparency Report™ Program is operated by Sustainable Minds® | Privacy policy

Carboline Global Inc.
2150 Schuetz Rd.
St. Louis, MO 63146
www.carboline.com/
314-644-1000