Fiber Reinforced Concrete - BarChip Environmental Management … · 2019-01-14 · 100% of underground mining operations in Australia had switched from steel to synthetic fibre reinforcement

BarChip Environmental Management Plan

Responsible Use of BarChip Macro Synthetic Fibre Concrete Reinforcement

www.barch ip.com

Environmental Management Plan BarChip Inc. 20182

1 INTRODUCTION.....................................................................................................................

1.1 Scope........................................................................................................................

1.2 BarChip Environmental Mission Statement.......................................................

1.3 BarChip Inc. .............................................................................................................

1.4 BarChip Synthetic Fibre - A Brief History............................................................

1.5 Typical Applications of BarChip Fibre.................................................................

2 ENVIRONMENTAL OVERVIEW...............................................................................................

2.1 Carbon Footprint of Steel and Synthetic Fibre Reinforcement.....................

2.2 Microplastics............................................................................................................

2.3 Use of Plastics in Construction............................................................................

3 LIFE CYCLE AND ENVIRONMENTAL RISKS........................................................................

3.1 Fibre Raw Materials................................................................................................

3.2 Manufacturing.........................................................................................................

3.3 Distribution and Transport of Packed Fibre......................................................

3.4 Storage......................................................................................................................

3.5 Concrete Mixing.......................................................................................................

3.6 Distribution and Transport of Mixed Concrete..................................................

3.7 Use and Application of BarChip Fibre................................................................

3.7.1 Sprayed Concrete..........................................................................................

3.7.2 Poured Concrete............................................................................................

3.7.3 Precast Concrete...........................................................................................

4 END OF LIFE MANAGEMENT.................................................................................................

4.1 Waste Production and Release of Fibres to the Environment.......................

4.2 Disposal.....................................................................................................................

4.2.1 Disposal in Landfill..................................................................................

4.2.2 Disposal Near or in a Water Body.........................................................

4.2.3 Recycling..................................................................................................

4.2.4 Incineration...............................................................................................

5 CONCLUSIONS AND RECOMMENDATIONS......................................................................

REFERENCES.........................................................................................................................................

Appendix A - SKM Carbon Footprint Analysis...............................................................................

Appendix B - Failure Modes and Effects Analysis........................................................................

Appendix C - Product Handling Flow Charts................................................................................

4

4

4

5

5

7

8

8

9

9

10

11

11

12

12

13

15

15

16

18

19

20

21

22

22

22

23

23

24

25

27

33

38

“Of all the plastics we produce every year and that is 300 million tonnes, that tonnage brings many benefits like lightweight parts in cars, aeroplanes, artificial body parts.

Plastics aren’t the enemy here, it’s the single use items and that’s 40% of all production of things that are used and discarded within a year.

I believe we can have and use plastics to our advantage without the accumulation of waste.”

Professor Richard Thompson - Marine Biologist Plymouth University

Environmental Management PlanBarChip Inc. 2018 3

Macro synthetic fibres, such as BarChip (shown in Photo 1), are being used more frequently as an alternative to steel mesh reinforcement. BarChip offers several advantages over steel mesh reinforcement and has successfully been used in a wide range of applications including major tunnels, mining, precast concrete manufacture, commercial flooring, marine infrastructure and civil infrastructure.

1.0 Introduction


Figure 1: BarChip synthetic fibre

This report outlines the typical applications of BarChip, providing details on some recent projects. The key environmental risks and mitigation strategies are identified throughout the manufacture, transport, use and disposal of BarChip. Finally, the best practice management techniques are discussed, promoting environmentally sustainable practices to minimise the potential environmental impact of BarChip.

BarChip is committed to the proper use of its product within the market place. This includes our commitment to produce zero waste and to ensure that no BarChip products enter or adversely affect land and marine environments. BarChip is working closely with all parties involved to achieve this goal. Resource efficiency starts with using waste as a resource, which is key to becoming more resource efficient. Landfilling is a waste of resources and should therefore be avoided for both recyclable and other recoverable consumer waste. BarChip adheres to this philosophy of resource efficiency. In consultation with our clients we will strive to:

• Stop all recyclable BarChip fibre being disposed of in landfill or marine environments;

• Support innovation in plastics recycling technologies to further increase global recycling initiatives;

• Continue the development of our “R-Series” recycled fibre line, with the ultimate goal of incorporating 100% recycled plastics as the source material for our synthetic fibre reinforcement.

1.1 Scope

1.2 BarChip Environmental Mission Statement


1.3 BarChip Inc. BarChip is a global operation with an extensive network of offices and distribution partners who have led the development of synthetic fibre technology from the walls of underground mines into every major construction sector globally. BarChip has been used in construction for nearly 20 years and similar products such as micro fibres (also manufactured from plastic) for much longer.

BarChip has pioneered nearly every major development of synthetic fibre technology, including fibre embossing, UV stabilisation, tensile strength and Young’s modulus development and recycled manufacturing. BarChip has developed a suite of application specific fibre products that is unmatched by any fibre developer in the market. Some recent project highlights include;

• The 1.2 km Devil’s Slide Road Tunnel, United States

• The 14.8 km Helsinki Metro West Extension, Finland

• The 9.0 km T-Connection Road Tunnel, Norway

• The precast segmental lining of the Santona Loredo water tunnel, Spain

• The precast segmental lining of the Malaga metro rail tunnel, Spain

• The BMW manufacturing plant concrete floor, Brazil

• The Toyota manufacturing plant concrete floor, Japan

• The HABOM aircraft maintenance floor, Turkey

• The precast grandstand elements of Debrecen Stadium, Hungary

• The Cero Somberero highway road pavement, Chile

• The 35 km Eastlink shared path, Australia

1.4 BarChip Synthetic Fibre - A Brief History

In recent years, steel reinforcement has been the most commonly used material for concrete reinforcement. Cracking in concrete that is reinforced with steel can become a durability issue by greatly reducing the effective service life of the concrete. These cracks allow the movement of moisture and deleterious materials such as chlorides into the concrete and this can cause corrosion of the steel reinforcement.

When steel corrodes, it not only loses cross-section and load bearing capacity, it also expands, and this expansion breaks the concrete apart from within. Corrosion of the reinforcement and deterioration of concrete properties reduces asset service life, resulting in premature replacement of concrete.

The National Association of Corrosion Engineers (2016) estimated the annual global cost of steel corrosion at 2.5 trillion dollars, with the cost in the USA alone estimated at USD 451 billion (Koch et al. 2016). It is therefore clear that alternative methods for concrete reinforcement are required to reduce the economic cost and environmental impact of corroding steel reinforcement.

As early as the 1960’s researchers began looking at micro synthetic fibres (non-structural fibres) as an alternative to steel reinforcement that could eliminate durability concerns from corrosion. However, it was not until the late-1990’s that manufacturing techniques and plastics technologies developed to the point where macro synthetic fibre (structural fibres) offered a performance equal to that of steel in concrete.

BarChip macro synthetic fibre was released to the market in 1996, primarily as a fibre for shotcrete reinforcement in underground mining. The first major project came in Australia in the early 2000’s at Northparkes mine and by 2015 100% of underground mining operations in Australia had switched from steel to synthetic fibre reinforcement.

This rapid transformation of industry standards was brought about by three critical factors.

1. Synthetic fibre reinforcement eliminated the durability problems associated with steel reinforcement,

2. BarChip synthetic fibre reinforcement offered a performance equal to or greater than steel reinforcement, and

3. BarChip synthetic fibre eliminated the need to set-up and install steel mesh, greatly improving on-site safety, especially in underground environments.

Macro synthetic fibre offers many benefits beyond these core values and this has seen the market grow into a mature global industry that is widely accepted as a concrete reinforcement. Today macro synthetic fibres are used to reinforce nearly every type of concrete application all over the world. BarChip macro synthetic fibre reinforcement is used to replace steel mesh reinforcement for the following key advantages:

• Durable and high strength – BarChip can provide greater resistance to deformation at higher deflections

• Corrosion free – exposed BarChip fibres will not degrade when exposed to moisture and air

• Improved concrete ductility – attributed to the technology of plastic over steel;

• Significant shrinkage and temperature crack control –due to the characteristic properties of plastic

• Price reduction - through decreased transport, labour and material cost

• Productivity efficiencies due to labour cost reductions as a result of eliminating all processes associated with steel reinforcement

• Reduced greenhouse gas emissions in production

• Eliminates concrete cover required for steel reinforcement, decreasing total concrete consumption

• Improved impact resistance and robustness - BarChip fibres reinforce the entire cross section, leaving no unreinforced and vulnerable concrete cover.


1.5 Typical Applications of BarChip Fibre

In order to properly review the environmental risk of BarChip we have identified each of the industry sectors where BarChip is used. BarChip is a virgin or recycled polypropylene fibre used as a replacement for steel mesh and steel fibre reinforcement. In many applications, BarChip can be installed at a lower cost and a significantly lower carbon footprint while still outperforming steel reinforcement. BarChip is used successfully in the following industries:

Sprayed Concrete

• Subterranean ground support – mining and tunnelling excavation, civil structures

• Slope stabilisation – road and rail cuttings, culverts, portals and high walls

• Vertical walls – commercial buildings, civil structures

• Swimming pools

Poured Concrete

• Commercial and industrial flooring

• Hardstands

• Roadway paving

• General paving

• Concrete track slab for rail, metro and trams

Precast Concrete

• Segmental tunnel linings

• Water storage tanks

• Road barriers

• Manholes

• Decorative elements

To date, after more than 15 years in major projects that when managed properly using simple solutions to identify risk situations, the likelihood of environmental contamination from the liberation of BarChip into the environment is extremely low. These solutions are discussed below.


2.0 Environmental Overview

2.1 Carbon Footprint of Steel and Synthetic Fibre

Reinforcement

BarChip products are used in place of (and alongside) traditional steel mesh and bar reinforcement. In 2013, BarChip commissioned Jacobs Engineering (formerly Sinclair Knight Merz) to calculate the carbon footprint of two products – BarChip 48 and BarChip 54 in comparison to steel mesh reinforcement. The key outcome of the investigation was the determination of the carbon dioxide emission per cubic meter of placed concrete.

The dosage rates utilised in the investigation were as follows:

BarChip:

• 3kg BarChip 48 per m³ of concrete;

• 8kg of BarChip 54 per m³ of concrete (plus 70kg of reinforcement steel in one scenario);

Traditional Reinforcement

• 2.8kg Steel per m² for flooring (with an assumed 150mm slab thickness);

• 140kg Steel Bar per m³ for structural applications

The study determined that the carbon footprint of BarChip reinforced concrete is lower than concrete reinforced traditional steel reinforcement. Specifically, and based on the assumptions made:

• BarChip 48 offers a carbon emission reduction of 74% over steel mesh in a 150mm slab; and

• BarChip 54 when used in conjunction with steel bar offers a 41% reduction in carbon emissions when compared to concrete reinforced exclusively with steel bar.

The carbon footprint of flooring reinforced by steel mesh varies depending on the slab thickness and how many layers of mesh are added. Table 1 below shows the carbon footprint to produce 1m³ with BarChip 48 reinforcement and traditional steel mesh.

The results show that in all slab thicknesses, BarChip 48 has a significantly lower carbon footprint. The SKM Carbon Report is reproduced as Appendix A.

Slab Thickness1m2 Slab with Steel

Mesh Reinforcement1m2 Slab with BarChip

ReinforcementBarChip Reduction

over Steel

100mm with 1 x mesh 4.87 kgCO2e 0.83 kgCO2e 83 %




Table 1: Comparison of Carbon Emissions for BarChip and Steel Mesh Reinforced Concrete


2.2 Microplastics It has been acknowledged that the accumulation of microplastics in the ocean is becoming an environmental issue. There are no reliable estimates on the inputs at a regional or global scale (Solomon, 2016), however it can be assumed that the trend is increasing as the global reliance on plastics increases. The process by which microplastics are produced is summarised as follows:

1. Plastics are lost or inappropriately discarded and migrate to marine environment;

2. Through physical, chemical and biological degradation, plastics are broken down to micro-sized particles, referred to as microplastics;

3. Microplastics are then consumed by low trophic fauna; then

4. Microplastics are transferred to higher trophic species through ingestion of lower trophic species.

Given the scale of use plastics have in most aspects of modern industries including construction, manufacturing, solutions to prevent environmental release of BarChip are required. Management actions, specific to the manufacture, use and disposal of BarChip are discussed in Section 4.

2.3 Use of Plastics in Construction

Materials used across all sectors of the construction industry are constantly developing, with technological advancements reducing the demand on natural resources, overall costs and improving product performance.

Polymers in particular have successfully replaced many materials in a wide range of applications, delivering safety, performance and economic advantages, and in many cases a decreasing to the overall environmental impact. The following are just some examples of plastic products that have replaced more expensive or less effective products to great effect in the construction industry:

1. Concrete reinforcement and curing products;

2. Geomembranes and liners;

3. Geotextiles and high performance drainage systems;

4. Geonets and grass reinforcement mats;

5. Pipes and ducting;

6. Structural members, supports, ladders and rails; and

7. Electrical conduits and insulation.

An example of civil construction areas using significant quantities of plastic include tunnelling and mining. Examples of products used and often discarded include: lifter tube, detonating cord, discarded PPE, plastic sheeting in concreting and general packaging waste. In terms of quantity, these products significantly outweigh the amount of waste BarChip contributes to a project.

Because of the amount of waste construction mining projects generate, both plastic and other, a holistic approach to waste management is required to accomplish environmental responsibilities and ensure all waste, including plastic components, are disposed of in a proper manner.


3.0 Life Cycle and Environmental Risks

This section describes the environmental risks BarChip may present throughout its life cycle and is reviewed with the use of a Failure Mode and Effects Analysis (FMEA). The FMEA is a method of identifying and analysing environmental risks using a step-by-step process to consider failure modes and their potential effects. Following identification of failure modes and effects, mitigation strategies can be implemented and residual risks determined. Key failure modes and mitigation strategies from the FMEA are provided in Appendix B for quick reference and are discussed below.

As a method of identifying the residual risk for each failure mode, the environmental risk for each activity part of BarChip’s life cycle have been rated with a Low, Moderate or High using symbols shown below.

The following life cycle stages have been examined in the FMEA:

1. Fibre’s raw material;

2. Manufacturing;

3. Distribution and Transport of Packed Fibre (prior to the addition of concrete);

4. Storage;

5. Concrete Mixing;

6. Distribution of Fibre Reinforced Concrete;

7. Use and application of BarChip in construction; and

8. End of life management.

The failure modes, effects and key mitigation strategies are identified below.


3.1 Fibre Raw Materials BarChip is manufactured using virgin or recycled polypropylene, a plastic produced from crude oil. BarChip does not produce raw polypropylene, but obtains polypropylene granules from material suppliers. The environmental management of obtaining and processing crude oil, and the subsequent production of polypropylene is outside the scope of this report. It is noted that millions of tonnes of virgin polypropylene are produced each year for use in a wide range of applications, and as a consequence stringent controls are implemented to ensure activities are environmentally responsible.

Our assessment of the environmental risk associated with sourcing and transporting the raw material to the manufacturing facility is low. See risk assessment flow chart Appendix C1.

3.2 Manufacturing The manufacturing process involves converting the plastic granules into yarn and then cutting the yarn into short fibres prior to packaging. The manufacture of BarChip is tightly monitored in a factory environment where the risk of environmental contamination is extremely low. Polypropylene granules are securely packaged and stored to mitigate the risk of release outside the factory environment. The granules are delivered to BarChip’s factory in sealed bulk containers and then decanted into hoppers feeding the melting process.

Process controls and monitoring techniques are used to minimise the volume of waste produced. The potential environmental risks of the waste produced are limited through regular inspections and maintenance of the collection systems. Measures to capture waste are employed to ensure environmental contamination does not occur. Waste and fibres that are collected are returned to the feedstock and remelted. In addition, rejected BarChip fibres are also returned to the feedstock, reducing waste and potential environmental harm.

BarChip is certified to and manufactured under the following international standards:

• ISO 9001:2015 – Quality Management System

• ISO 14001:2015 – Environmental Management System

Together these systems ensure continuous improvement of our manufacturing processes and set the framework for effective environmental management controls throughout the entire manufacturing process.

Our assessment of the environmental risk associated with manufacturing is low. See risk assessment flow chart Appendix C1.


3.3 Distribution and Transport of Packaged

Fibre

The transportation of fibres over long distances presents an increased risk of environmental release. Because the fibres are transported in bulk (40 ft. container or lorry load), any release of BarChip during transport could result in large quantities of fibre spread over expansive areas if not managed properly.

BarChip has abridged post production transport risks by implementing the following management strategies:

• Suitably packed in tightly sealed packaging to prevent loss of fibre

• Shipped on recyclable plastic pallets which are easily and securely stacked indoors or outdoors with no deterioration

• All pallets are shipped with waterproof tarpee covers made from waterproof and weatherproof PE sheeting

The packing and shipping methods employed by BarChip minimises reasonable risk of environmental release during warehouse storage, transport and storage at construction sites. With these solutions, together with no known loss of fibres while being transported in 15 years, it is highly unlikely that fibres would be released to the environment.

While unlikely, extreme events such as a truck roll-over or pallets lost off ships require adequate risk minimisation strategies also. Fibres left at sea if a pallet was lost from a shipping container would be difficult to recover. Mitigation of this risk is therefore undertaken through proper loading of the ship and storage of pallets in sealed shipping containers. If a container is lost at sea the fibres should be locked within the container, resulting in a low risk of widespread ocean liberation.

BarChip fibres lost on land as a result of unexpected bag breakage could be manually recovered by hand or machinery and would likely not spread over large distances if a proactive approach to recovery of the material was undertaken.

Our assessment of the environmental risk associated with transport is low. See risk assessment flow chart Appendix C1.

3.4 Storage During storage, the risk exists that weather or fauna could disperse fibres. Proper storage on-site is therefore critical. As discussed in Section 3.3, BarChip is delivered in secure packing, resistant to weather and fauna. Consequently, while BarChip remains in its original packaging, the risk of environmental release is low.

When stored outdoors, unopened pallets should be appropriately secured from weather and fauna risks. Individual BarChip paper bags separated from pallets


are subject to deterioration by moisture and could be easily opened by fauna. Paper bags must therefore be suitably repackaged to prevent damage.

Secondary packaging must be waterproof to prevent access by animals. Alternatively, bags may be stored indoors in a secure area, thus minimising the risk of environmental release.

Our assessment of the environmental risk associated with storage is low. See risk assessment flow chart Appendix C2 to C5.

Figure 2: BarChip Pallets in Storage

3.5 Concrete Mixing During batching and mixing BarChip fibres could be susceptible to release to the environment if appropriate management practices are not employed. Fibres dropped in a concrete batching area could migrate to waterways or be consumed by animals resulting in environmental harm. If released to the environment, recovery of all fibres may be difficult and consequently prevention of fibres being dropped is preferable. To minimise fibre liberation during batching and mixing, users should:

• Have a dedicated dosing platform/area;

• Have a dedicated wash out area;

• Have a filter system established to separate fibres from the wash out water;

• Regularly sweep and clean mixing and washout areas;

• Regularly clean filter systems.

BarChip has minimised the risk of dropped fibres being released during mixing through supplying fibre in premeasured packaging. Fibres are supplied in 2.5 kg, 3kg and 5 kg mulchable paper bags which are added “bags and all” and dissolve into the concrete during mixing. BarChip is also supplied in puck form which is added to the concrete though controlled automated dosing machines (shown in Figure 3). By eliminating the need to open bags and containing fibre within packaging, BarChip has minimised the risk of fibres being liberated during mixing. This management technique can be used with any standard method for


mixing concrete including:

• by hand;

• machine; and

• in readymix.

Mixing concrete by hand or in small rotating drums, and transporting by wheelbarrow presents the greatest risk as manual handling is required. Any fibre volume dropped during hand mixing would be very low and easily recovered on the spot. Larger batches including readymix concrete are often automated processes, mixed in controlled environments and applied via a pump and hose. Without manual handling of concrete there is a low risk of concrete being spilt.

Following the procedures mentioned above further minimises the risk of fibre liberation. BarChip’s method of supplying fibre in pucks or paper bags, both of which are added to the concrete mix directly, has negated most of the risks associated with fibres being released to the environment during batching and mixing.

Figure 3: BarChip Automatic Dosing System (left) and mulchable bags (right).

Our assessment of the environmental risk associated with mixing is low. See risk assessment flow chart Appendix C5.


3.6 Distribution and Transport of Mixed

Concrete

Generally, once the fibre has been mixed into the concrete, transportation to site is accomplished using a concrete mixer truck. Extreme events such as truck roll over could possibly result in loss of a large amount of fibre reinforced concrete being released to the environment. A concrete truck roll over presents a high risk regardless of the presence of BarChip, with significant effort required to recover concrete. It would be highly unlikely that BarChip would separate from spilt concrete and in this event the most significant environmental risk would be the concrete rather than BarChip.

Concrete mixed by hand or with a barrel mixer is usually transported by a wheelbarrow or similar. In the event of spillage, the volume of concrete would be very low and easily cleaned and contained on the spot.

Our assessment of the environmental risk associated with transport of mixed concrete is low. See risk assessment flow chart Appendix C1.


3.7 Use and Application of BarChip Fibre

This section assesses the primary applications for the use of BarChip in the construction industry which have been identified as:

1. Sprayed Concrete;

2. Poured Concrete;

3. Precast Concrete

Similar to the peruse management discussed above, each of the above activities is broken down with a step by step process to identify the activity and assess the environmental risk of fibre contamination associated with that activity. The activity can then be cross referenced with both the FMEA and the work flowchart for easy reference. Each step has been risk assessed with the likelihood of contamination.


3.7.1 Sprayed Concrete Sprayed concrete, also referred to as shotcrete, is a specialised concrete pneumatically applied at high pressure onto a wall or substrate. It is predominately used in mining and tunnelling applications but also used in smaller scale civil applications such as slope stabilisation works and swimming pools. Typically, underground works present a far lower risk of fibre liberation as they are not exposed to rain, storm water runoff or bio intrusion.

During concrete spraying, it is likely that fibres will inadvertently be displaced outside of the immediate construction area, primarily as a result of rebound. Rebound is cement, aggregate or fibre which ricochets off the surface during application as it collides with the hard surface or with the particles themselves. Fibres may also be liberated through on-site activities such as equipment washout and rebound/muck disposal. To mitigate the risk of fibre loss users should undertake the following strategies when applying sprayed concrete:

Education and Training

Ensure the work force is informed of all mitigation controls and their responsibilities and to operate within those controls. Ensure the workforce understands the importance of “keeping an eye” on all activities to ensure any rebound or waste problems do not get out of hand. Most projects require that nozzlemen are specifically trained for the task and must obtain a “nozzleman’s certificate”. This level of training will help to ensure not only a high quality of finished work but a reduction in the causes of environmental contamination such as rebound.

Reduce Rebound

Generally, shotcrete rebound accounts for some 3% to 5% of the total concrete sprayed. The quantity of shotcrete can be significantly reduced by correct spraying techniques as follows:

• accurate nozzle distance (1 to 2 m from face), correct nozzle angle (90 degrees to substrate);

• correct air pressure and volume (10 – 12 m3/min at a minimum of 100 PSI); and

• an optimised shotcrete mix design.

The application techniques are shown in Figure 4.

Figure 4: Shotcrete application techniques to reduce rebound.

Dedicated Equipment Washout Areas

Use a dedicated wash out area where the washed-out material ensures waste is contained and collected. The collected materials can then be disposed of in the appropriate manner. Figure 5 shows examples of waste capturing methods for washout areas.

Figure 5: Examples of different concrete capture methods.

Ground Coverings

Where practical, tarps should be laid prior to the application of spray concrete to collect the rebounded material, which allows for quicker and more effective site clean-up.

Sediment Control Barriers

To ensure any fibre rebound will not disperse great distances from the spray face, the use of control barriers enables capture of loose fibre in the event of rain and storm water run-off. Examples of these sediment control barriers are shown in Figure 6.

Figure 6: Examples of different sediment control barriers.

Where projects are located near a river or a large water mass other containment and capture methods can be used such as a floating pontoon shown in Figure 7.

Figure 7: Floating pontoon. Note the direction of water movement is from right to left and floating debris is collected in the containment area ready to be disposed of appropriately)


Regular Cleaning

Work sites should be regularly swept and cleaned to prevent a build-up of rebound materials.

Reduce Fibre Dose Rates

High performance synthetic fibres require lower dose rates to achieve performance targets. By using a premium fibre, such as BarChip, the dosage rates are reduced thereby reducing risks of fibre liberation.

Rebound / Muck Disposal

During application of shotcrete it is possible for fibres to be lost and mixed with the excavation material, primarily through rebound and less often due to spilt concrete. Once in the muck pile, BarChip could be lost from the construction site through wind or rain eroding away the muck pile. Additionally, removal and repurposing of polluted soils could present additional risks and as such users should:

1. Immediately clean up the spill area and recover any spilt concrete.

2. Take all possible efforts to prevent any rebound including fibres contaminating the muck pile in the first instance.

3. Remove and dispose of contaminated soil in a method where fibres will be contained.

4. Dispose of contaminated soil or muck in a quarantines stockpile until its authorised disposal.

5. Dispose of muck and contaminated soil is discussed in detail in Section 4.2.

Our assessment of the environmental risk associated with the application of sprayed concrete is moderate. Control measures are used to eliminate this risk. See risk assessment flow chart Appendix C2 for control strategies in tunnelling applications.

3.7.2 Poured Concrete BarChip is used to replace welded wire mesh in commercial and industrial flooring, residential flooring, hardstands, metal deck and other slab on grade applications. Typically, in the construction of poured concrete applications, premixed concrete is supplied to the construction site. Prior to pouring, construction of formwork is required to contain the fresh concrete before setting. Proper and secure formwork reduces environmental risk through ensuring fibres are contained within the formwork.

In the event of fibre reinforced concrete being spilt or falling outside formwork, BarChip fibres will be contained within the concrete itself and the risk of wider liberation is low. Following a spill of concrete, immediate clean up and recovery of the site should be undertaken.


Most flooring applications are covered by an existing roof construction over the building. However, potential exists that high rainfall events during construction could result in BarChip being released to the environment. This risk is mitigated through:

• Checking forecasts prior to delivery of concrete and delaying construction if required.

• Erection of a sediment control barrier to capture run-off, including fibre reinforcement.

Our assessment of the environmental risk associated with placing poured concrete is low. See risk assessment flow chart Appendix C5 for management strategies for commercial and industrial floors.

3.7.3 Precast Concrete Precast concrete elements such as pipes, tanks and structural panels are widely used in civil construction. Precast concrete items can be manufactured in a controlled environment with less labour and reduced production time.

Precast concrete manufacturing facilities have the potential to accumulate waste though continuous batching and pouring of concrete. Accumulated waste may migrate to the environment impacting fauna and environmental aesthetics. Stringent operating conditions are therefore required to ensure the environmental impact of precast concrete manufacturing facilities are low.

A benefit of precast concrete manufacturing is the ability to install efficient and permanent waste collection and separation systems. These controls may comprise gross pollutant traps enabling the collection and removal of loose BarChip fibres. Waste generated in precast manufacturing facilities are easily reused or disposed of. Consequently, the waste generated from precast manufacturing facilities is likely to be low.

Preexisting production controls in most precast concrete manufacturing facilities will enable removal of BarChip with little or no modification required. Users of BarChip fibre in precast facilities should ensure fibres are stored securely and conduct regular cleaning.

It is possible that very small amounts of fibre could be lost during the production of individual precast items. These fibres will be in the immediate vicinity of the mixing station and can be collected through regular cleaning.

Our assessment of the environmental risk associated with precast concrete manufacture is low. See risk assessment flow chart Appendix C4.


4.0 End of Life Management

End of life management of BarChip includes loose fibres and demolition of structures containing BarChip. BarChip and BarChip reinforced concrete may be beneficially reused though material recovery facilities, recycled or incineration for energy recovery. Alternatively, materials may be disposed of at a landfill.

Improper disposal of BarChip can result in environmental damage. The management of these risks and appropriate management actions are outlined below.

4.1 Waste Production and Release of Fibres to the

Environment

Appropriate handling of fibres is imperative to ensure BarChip fibres are not released into the environment, especially during transport where BarChip fibres could be spread over large distances. Waste production is possible at any stage of the products life cycle including:

• material extraction;

• manufacture;

• transport;

• storage;

• mixing;

• application; and

• disposal or recycling

Plastics have been shown to cause negative impacts to fauna through entanglement and ingestion. Most records indicate the effects of plastic debris has on wildlife relates to entanglement, rather than ingestion (AUS EPA, 2016). Due to its shape and length, BarChip does not present a significant risk to entanglement and although it could be consumed by fauna this is highly unlikely. It is unlikely that a single fibre would present significant risk to fauna and would only present terminal risk when combined with other plastics. There are no known toxicological hazards for polypropylene however BarChip may be a health hazard to fauna through ingestion of numerous fibres due to its size and shape. The risk of fauna consuming fibres is mitigated through implementing adequate management principals appropriate to each stage in the products life cycle.

BarChip is less dense than water and will float. Once in a marine environment, this would result in high mobility of the fibre and accelerated degradation. The limited numbers of BarChip that were lost from construction sites would therefore likely be washed up on shores where it could be collected and placed in landfill or recycled. The risk and consequence of release of BarChip in each of these stages is outlined below.


4.2 Disposal If recycling or reuse is not possible, loose BarChip fibres and hardened concrete containing BarChip may be safely disposed of in a landfill. In terms of sustainable manufacturing processes, the priority for disposal method should be as follows:

1. Reuse;

2. Recycle; and

3. Methods involving loss or destruction of material (incineration or landfill).

It is noted that all plastic products may be recycled a certain number of times and hence must eventually be disposed of. The management techniques for each of these disposal methods are outlined below. See risk assessment flow chart Appendix C9.

4.2.1 Disposal in Landfill The primary management aspect to rubbish management at a landfill is preventing loss of trash to the environment. These management aspects are employed in transport of the waste, sorting and processing of waste, placement in landfill and up to covering and rehabilitation of landfills. BarChip fibres do not present risks which are exclusive to the product however as all waste has potential to mobilise, risk prevention strategies are required. In contrast, the low surface area to weight of BarChip limits the risk of the fibre to becoming windblown.

Following transport to the site (for which management aspects remain as discussed in Section 3.6), trash may be dumped on the tip face. Once on the tip face immediate compaction and subsequent covering of waste with soils or liners prevents liberation of wastes. In this way, it is unlikely that fibre and hardened concrete containing BarChip would be transported off site.

Self-managed landfills such as found at remote construction or mine sites implement the same waste management practices, although at a reduced scale. The quantities of fibre and hardened concrete containing BarChip disposed at these remote facilities would be insignificant, as most of the product is consumed underground. Waste material generated in underground mines are kept to a minimum, and disposed underground where the risk of mobilisation is low. In summary, the following best practice landfill operational procedures would reduce the risk of BarChip being released to the environment:

• The area of exposed soils and waste should be minimised;

• Reduce operations on dry, windy days;

• Where practical, install wind barriers and enclosures to deflect wind from the working face or the landfill;

• Apply a daily cover to the waste while continuously compacting the waste;

• Inspect litter fences, perimeter fences and gates and clear litter as required;

• Retrieve all litter that leaves the site as soon as practicable;

• Install trash filters to sedimentation dams to prevent litter being washed or pumped into watercourses;


4.2.2 Disposal near or in a water body

Excavated earthwork materials such as tunnel excavation and muck are often used for land reclamation purposes. When used in this application, risk exists that fibres could migrate to water bodies where they could be transported. BarChip fibres are less dense than water and hence would float. Once outside the construction area, the contractor has little chance of recovering fibres and therefore controls are required to ensure BarChip is contained on-site. Therefore, when earthworks containing fibres such as tunnel excavations or muck are used for reclamation purposes, or disposed of in a water body, there is a risk of liberation and management strategies to reduce this risk are required.

In order to minimise the risk of fibres being released to the environment, first and foremost the management strategies discussed in Section 3 should be utilised. Where it is likely soil around construction works will be repurposed or removed, a detailed management and disposal plan would assist to identify potentially contaminated soils and identify the management actions to prevent liberation of these fibres.

As a final defence, sediment and silt reclamation devices may be employed for separation and filtration of contaminated runoff. Examples of these devises are shown in Figures 8 to 10.

Figure 8: Sediment control barriers and silt fences.

Figure 9: Floating barriers

In deep waterways silt curtains are used to provide a barrier from the surface to the floor of the water body. This prevents materials being washed underneath the barrier. Silt curtains can be particularly effective in tidal areas with fast moving water.

• Implement a water management plan that allows for the removal of litter prior to off-site discharge; and

• Undertake regular monitoring to ensure preventative measures implemented operate as specified.


Figure 10: Silt Curtain Systems

Proper management techniques can minimise the risk of BarChip being liberated from soils during land reclamation. The key management technique is related to construction staging with the far exterior boundary of the reclaimed land footprint constructed first with fibre free clean fill. This is most often done with barge pumps. Once complete, fill containing fibre material can be safely deposited within the walls with no risk of liberation. The final topping layer should once again be with fibre free clean fill to seal any loose materials under the surface.

Figure 11: Back-fill barrier walls

4.2.3 Recycling Recycling of material reduces crude oil consumptions and facilitates in reducing landfill demand. As BarChip does not present unique risks during recycling, standard precautions employed by recycling facilities would prevent waste entering the environment.

Waste BarChip fibres generated through surplus stock, damaged stock or fibres recovered in waste collection systems could easily be recycled as BarChip fibres where it was possible to return waste to a facility for re-melting and return to feed stock. Recycled polypropylene could otherwise be utilised for any other polypropylene product.

Separation of BarChip from concrete during demolition can be difficult. It is noted however that fibre reinforced concrete could be crushed and repurposed as drainage aggregates or road subgrades. The risk of environmental pollution during reuse may be managed through ensuring fibres liberated during concrete crushing are recaptured. Washing of crushed concrete aggregates ensures loose fibres are regained.

See risk assessment flow chart Appendix C8.

4.2.4 Incineration In some instances, incineration may be an appropriate management strategy, where BarChip cannot be recycled. Again, during incineration, BarChip does not present any risks exclusive to the product and can therefore be prevented from entering the environment through employing industry standard handling techniques.


5.0 Conclusions and Recommendations

Numerous projects incorporating BarChip reinforced concrete have proven the product to be durable and suitable for replacing concrete mesh reinforcement. The extensive testing which has been undertaken by BarChip and other third parties further demonstrates that BarChip can withstand chemical, physical and biological degradation and will often outlast alternative reinforcement materials.

Today plastics are used throughout the construction industry, not excluding the concreting industry with plastic lining of the raft slab and plastic chairs used for supporting steel reinforcement. BarChip fibres do not present risks in manufacturing, transport, construction or disposal which is uncharacteristic of other wastes and therefore modifications to existing operating procedures in most cases are not required.

Key management strategies outlined in this document reduce the environmental risk of BarChip. The management principals discussed are considered best practice for environmental management and have been developed to provide a high level of environmental performance. These practices apply to BarChip staff, distributors, contractors and landfill operators (see Appendix C).

Through educating all parties involved including staff, distributors and contractors on the potential environmental impacts of BarChip, the environmental risks are further reduced. Incidents such as the release of fibres to the environment, should be reported to BarChip for the continual development of the environmental management policy and practices.


References

1. Australian EPA (2016). Impacts Of Plastic Debris On Australian Marine Wildlife. [online] available at: https://www.environment.gov.au/marine/publications/impacts-plasticdebris-australian-marinewildlife [Accessed 30 Aug. 2016].

2. Elasto Plastic Concrete (2012). The History of Fibre Reinforcement – Elasto Plastic Concrete. [online] available at: http://www.elastoplastic.com/index.php/the-history- offibrereinforcement [Accessed 20 Aug. 2016]

3. Findley, W. N.; Davis (2013), F. A., Creep and relaxation of nonlinear viscoelastic materials. Courier Corporation.

4. GESAMP (2015). Sources, fate and effects of microplastics in the marine environment: a global assessment. [online] available at: http://ec.europa.eu/environment/marine/goodenvironmental-status/descriptor-10/pdf/GESAMP_microplastics%20full%20study.pdf [Accessed 1 Aug. 2016].

5. Hansen Erik (2013). Hazardous Substances in Plastic Materials. [online] available at: http://www.miljodirektoratet.no/old/klif/publikasjoner/3017/ta3017.pdf [Accessed 22 Aug. 2016]

6. Koerner, R. M. (2005). Designing With Geosynthetics. New Jersey, Pearson Education, Inc. [7] Polymerdatabase.com (2015). “Properties Of Polyamides”. [online] available at:

7. http://polymerdatabase.com/polymer%20classes/Polyamide%20type.html [Accessed 31 Aug. 2016].

8. Starr, Trevor F and Mary Starr (1998). Thermoset Resins For Composites. Abington, England, Woodhead Pub.

9. Yin, Shi et al (2015). “A Life Cycle Assessment Of Recycled Polypropylene Fibre In Concrete Footpaths”. Journal of Cleaner Production 112.


Environmental Management Plan 201726

Since 2000, BarChip macro synthetic fibre has been safely used in over 5,000 km of underground works.

Appendix A


Elasto Plastic Concrete – BarChip 48 and 54 Carbon Footprints

PAGE 1

Introduction

SKM was commissioned in 2013 to calculate the carbon footprint of two Elasto Plastic Concrete (EPC) products – BarChip 48 and BarChip 54. These products are polymer fibres which are used to provide reinforcement to concrete used in a range of applications. BarChip products are used in place of (and alongside) traditional steel mesh and bar reinforcement. EPC wished to determine the scope of the environmental benefit of its products over traditional reinforcement options.

Product Carbon Footprinting

A product carbon footprint is an inventory of the greenhouse gas emissions and removals at each stage of a product life cycle. Greenhouse gases include:

Carbon dioxide – the most abundant greenhouse gas typically generated from combustion of fuel for energy generation and transport purposes;

Methane – typically generated from the decomposition of organic material; Nitrous oxide – a by-product of combustion and a medical gas; Synthetic gases – such as refrigerants used in air conditioning systems and insulating

gases used in metal manufacture and electrical switchgear. For the purposes of this study, the most relevant greenhouse gas is carbon dioxide, which is most commonly produced through combustion.

The carbon footprint typically assesses the emissions of greenhouse gases from the initial extraction of all raw materials, through each life cycle stage to the ultimate disposal of the product (and the emissions that arise from decomposition of the product. This is typically referred to as a ‘cradle to grave’ carbon footprint.

For this study, the emissions have been calculated up to the point that the BarChip is manufactured and ready for distribution. This is commonly referred to as a ‘cradle to gate’ carbon footprint, and allows users to use the data to suit their own application. This is shown in the diagram below:

= Cradle to grave

= Cradle to gate

SUMMARY

This study compared the carbon footprint of BarChip synthetic fibres as reinforcement for concrete products with traditional steel reinforcement.

The study determined that the carbon footprint of 1m3 of reinforced concrete is lower when BarChip is used than with traditional steel reinforcement.

Specifically:

BarChip 48 offers a reduction of between 66% and 83% over steel mesh; and

BarChip 54 used in conjunction with steel bar offers a 41% reduction over use of steel bar alone.

The carbon footprint for BarChip products is calculated as:

BarChip 48 – 8.33 kgCO2e / m3 concrete (2.78kgCO2e / kg BarChip 48); and

BarChip 54 – 20.20 kgCO2e / m3 concrete (2.52kgCO2e / kg BarChip 54).

Raw Materials

Manufacture Product Usage

Disposal


Note: BarChip Inc. formerly traded under the name Elasto Plastic Concrete.


PAGE 2

Barchip 48 and 54 – Carbon Footprint

Carbon footprints are calculated to determine the potential contribution of a product, service or organisation to climate change, which options have the lowest carbon footprint and to assist in identifying options for carbon footprint reduction.

EPC believes that its BarChip range of products have a lower carbon footprint than traditional reinforcement options, and therefore engaged SKM to confirm this assertion and calculate any savings. Users of BarChip products can use the following results in understanding the carbon footprint of their construction project.

Methodology

In order to make meaningful comparison between different products that can be put to the same use, a functional unit is defined to ensure that all impacts are scaled to the quantity of the product that is needed to perform a set function. It is important that this functional unit provides a fair comparison between different products.

In the case of BarChip, it would not be appropriate to compare different types of reinforcement on their weight alone, as different weights of each option are required for specific purposes. For this study we have therefore chosen the functional unit as being the reinforcement needed for 1m3 of concrete. All impacts are therefore scaled to this value. BarChip products are used in a range of applications where they can be a partial and direct replacement for steel. The comparisons made in this document assume these scenarios.

The emissions were calculated through defining the supply chain of BarChip and steel reinforcement, and gathering emissions factors to represent the carbon emissions at each stage. Emissions factors are typically publically available, and define the aggregated greenhouse gas emissions of a unit process. The aggregated emissions are reported as kilograms of carbon dioxide equivalents (kgCO2e – all greenhouse gases are converted into the ‘equivalent’ of carbon dioxide).

The carbon footprinting process is aligned with carbon footprinting standards PAS2050 and ISO14067. The stages included are:

Oil extraction and production of polypropylene resin; Transport of the resin to the BarChip factory in Indonesia; Manufacture of BarChip; Within the results we have also provided an indication of the greenhouse gas emissions associated with:




PAGE 3


Manufacture of concrete of varying grades; and Manufacture of steel reinforcement (to provide a comparison – no travel emissions

associated with steel have been included). The following products were studied: 1) Flooring concrete reinforced with BarChip 48; 2) Flooring concrete reinforced with steel mesh reinforcement (SL72 mesh at 2.8kg / m2); 3) Structural concrete reinforced with BarChip 54 only; 4) Structural concrete reinforced with BarChip 54 and steel bar; and 5) Structural concrete reinforced with steel bar alone (140kg / m3 reinforcement bar). Results

The results of the assessment are shown in the figure below:

The above is based on the following dosage rates:

BarChip: 3kg BarChip 48 per m3 of concrete; 8kg of BarChip 54 per m3 of concrete (plus 70kg of reinforcement steel in one scenario);

Traditional Reinforcement: 2.8kg Steel per m2 for flooring (with an assumed 150mm slab thickness); 140kg Steel Bar per m3 for structural applications

The study determined therefore that the carbon footprint of 1m3 of reinforced concrete is lower when BarChip is used than with traditional steel reinforcement.

Specifically, and based on the assumptions made:

BarChip 48 offers a reduction of 74% over steel mesh in a 150mm slab; and BarChip 54 used in conjunction with steel bar offers a 41% reduction over use of steel bar

alone.



PAGE 4


The carbon footprint for BarChip products is calculated as:

BarChip 48 – 8.33 kgCO2e / m3 concrete (2.78kgCO2e / kg BarChip 48); and BarChip 54 – 20.20 kgCO2e / m3 concrete (2.52kgCO2e / kg BarChip 54).

When the emissions associated with concrete manufacture are added in, the relative carbon footprint of 1m3 of concrete are shown in the following graph:

The carbon footprint of flooring reinforced by steel mesh varies depending on the slab thickness (and how many layers of mesh are added. The table below shows the carbon footprint of the reinforcement for 1m3 concrete for BarChip 48 alongside traditional steel mesh options:

Slab Thickness 1m2 Slab with Steel Mesh Reinforcement

1m2 Slab with BarChip Reinforcement

BarChip Reduction over Steel

100mm with 1 x mesh

4.87 kgCO2e 0.83 kgCO2e 83%

150mm with 1 x mesh

4.87 kgCO2e 1.25 kgCO2e 74%

200mm with 1 x mesh

4.87 kgCO2e 1.67 kgCO2e 66%

200mm with 2 x mesh

9.74 kgCO2e 1.67 kgCO2e 83%

The results show that in all slab thicknesses compared, BarChip 48 has a lower carbon footprint.

Source of Emissions Factors

The carbon emissions factors for this study were derived from a range of sources including:

Plastics Europe For polypropylene (PP) and low density poly ethylene (LDPE – pallet shrink-wrap)

The UK Department for Environment, Food and Rural Affairs (Defra) 2013 Emissions Factors


PAGE 5


For Ship and Articulated Truck freight; and Indonesian Electricity grid emissions factors

Bath Inventory of Carbon and Energy For paper emissions factors

Australian Green Infrastructure Council For steel bar and mesh emissions factors

The International Reference Life Cycle Data System (ILCD) For timber (used as a pallet)

Limitations Statement

SKM derived the data in this report from publically available data sources, and from information provided by EPC. The passage of time, manifestation of latent conditions or impacts of future events may require re-evaluation of the findings, observations and conclusions expressed in this report.

In preparing this report, SKM has relied upon and presumed accurate certain information (or absence thereof) relative to the use of BarChip products as a replacement for steel reinforcement. Except as otherwise stated in the report, SKM has not attempted to verify the accuracy or completeness of any such information.

No warranty or guarantee, whether express or implied, is made with respect to the data reported or to the findings, observations and conclusions expressed in this report. Further, such data, findings, observations and conclusions are based solely upon information available in the public domain in existence at the time of the investigation.

This report has been prepared on behalf of and for the exclusive use of EPC, and is subject to and issued in connection with the provisions of the agreement between SKM and EPC. SKM accepts no liability or responsibility whatsoever for or in respect of any use of or reliance upon this report by any third party.


Appendix B


1-2

Virtually no impact.Extremely low probability.

3-5

Very low impact.Very low probability.

6-10

Low Impact.Low Probability.

11-15

Medium Impact.Medium Probability.

16 +

High Impact.High Probability.

Probability Score


Function ID Function Failure Type Potential Impact

Risk Without Controls

Recommended Actions Responsibility Time Frame for Action

Revised Risk With Controls

Severity(1 Low Impact

-10 High Impact)

A

Potential Cause

Probability of Occurrence (1

Low Probability - 10 High

Probability

Detection Mode

Probability of Detection (1

high probability - 10 low

probability) C

Risk Priority Number

(RPN) 1 - 1000

A x B x C

Revised Severity A

Probability of Occurrence

B

Probability of Detection

C RPN

1Manufacturing

and Storage (Section 3.2)

1.1 Stored fibres are exposed to wind and rain

Potentially high quantities of fibres are liberated and

released to the environment8 Storage bags

degrade or break 4 Identified at site by inspection 5 160 Routine inspections of stored fibres (see section 3.4) BarChip While stored 1 1 1 1

1.2 Stored fibres are exposed to UV degradation

Physical properties are reduced prior to usage of fibres 5 Improper storage

of fibres 2Visual inspection of fibres identifies chalking or other

physical flaws5 50 Store fibres as to minimise UV exposure

(see sections 3.4) BarChip While stored 1 1 1 1

1.3 Disposal of fibres not passing QC

High quantities of waste produced incurring disposal cost and airspace

consumption at landfill4 Manufacturing

techniques 2 Identified within manufacturing QC process 1 8

Adjust manufacturing techniques as necessary to minimise waste (see section

3.2)BarChip Manufacturing 3 1 1 3

1.4 Sourcing and manufacturing of raw material causing high emissions

Release of green house gasses 1Processing and

manufacturing of polymers

1 Air quality monitoring at manufacturing facility 1 1 Assess viability for the use of recycled

polymers BarChip Manufacturing 1 1 1 1

1.5 Waste generation in manufacturing facility during QC processes

Disposal of large quantities of fibres 4 Manufacturing techniques 4 Identified during manufacturing 1 16 Recycle fibres not passing QC (see

sections 4.2.3) BarChip Manufacturing 1 3 1 1

2 Transport (Section 3.3)

2.1 Fibres are lost from vehicle during transport Fibres pollute environment 6 Improper

packaging of fibres 2 Likely detected once received by distributor or contractor 9 108

Store and transport fibres in durable bags. Ensure bags are not damaged during

transport. (see sections 3.4)

BarChip, distributors,

transport companyPrior & during transport 3 1 2 6

2.2 UV degradationReduced strength of fibres and consequently concrete strength

reduced6

Fibres exposed to excessive UV during storage

1 N/A 1 6Packaging and add stabilisers to fibres. Store fibres out of direct sunlight. (see

sections 3.4)

BarChip, distributors, contractor

Manufacture to installation 1 1 1 1

2.3 Storage bag is punctured by fibres during transport Fibres pollute environment 6 Poor quality

packaging of fibres 3 Visual inspection before or during transport 5 90

Transport fibres in heavy duty bags. Undertake inspection of packaging prior

to transport. (see sections 3.4)BarChip, distributors Prior to transport 1 1 1 1

3 Construction (Section 3.6)

3.1 During spray application on dry land, fibres are liberated Fibres pollute environment 6

Wind, incorrect concrete mix, rain, unskilled

labour or incorrect application

5 Visual inspection during or following the spray process 8 240

Make effort to minimise rebound as per “Recommended practice: shotcreting in Australia”. Undertake inspection of work site following completion and clean up

rebound. (see section 3.7.1)

Installer of concrete

Rebound monitored during application with adjustments

taken where excessive rebound is identified final inspection

undertaken at the end of construction

2 2 1 4

3.2 Application in marineenvironment causes fibres to be washed into waterway

Pollution of waterways 9

Incoming tideover wet concrete excessive rebound or wasted concrete

8 Visual inspection during placement of cement 8 576

Control rebound. Where possible divert water. Undertake construction during

small tides and not before rainfall events. (see section 3.7.1)

Installer of concrete Before and during placement of cement 5 2 3 30

3.3 Incorrect dosage rates for fibres used

Concrete properties are lower than required - concrete service life

reduced7

Inaccurate measurement of

fibres3 Identified by weak concrete,

premature cracking or failure 7 147 Add premeasured bags or pucks (see section 3.5) Installer of concrete Immediately prior to placement 3 1 5 15

3.4 Fibres not evenly dispersed in concrete

Concrete not concrete properly reinforced 8 Inadequate/

improper mixing 2 Visual inspection of concrete prior to placement 2 32

Undertake concrete mixing as per manufactures guidelines (see sections

3.5)Installer of concrete During mixing 5 1 1 5

3.5 While stored at site, bags are broken

Fibres are blown by wind or rain, or are transported by fauna 6 Bag strength low,

bio- intrusion 3 Visual inspection by site personnel 4 72

Store fibres in durable bags. Appropriately store fibres at site. (see

sections 3.4)

BarChip, distributor, installer of concrete Prior to distribution 5 1 2 10

3.6 Wastage, due to over ordered concrete

Disposal of fibre reinforced concrete required 1 Over-ordering

concrete 8 Likely identified during construction 3 24 Ensure ordered concrete is as accurate

as possible Installer of concrete Before ordering 1 5 1 5

3.7 Fibres dropped during mixing process Fibres pollute environment 1 Lack of care during

mixing 4 Dropped fibres seen on ground 2 8 Take care not to allow fibres to be dropped (see section 3.5)

BarChip, installer of concrete During placement 1 2 1 2

3.8 Concrete segregation Pollution of environment with concrete and fibres 6

Release during various application

methods8 Wasted concrete seen on site 1 48 Clean-up waste. Minimise segregation of

concrete. (see sections 3.7) Installer of concrete Immediately after spill 1 5 1 5






-10 High Impact)

A

Potential Cause



Probability

Detection Mode



probability) C


(RPN) 1 - 1000

A x B x C

Revised Severity A


B


C RPN

1Manufacturing

and Storage (Section 3.2)

1.1 Stored fibres are exposed to wind and rain

Potentially high quantities of fibres are liberated and

released to the environment8 Storage bags

degrade or break 4 Identified at site by inspection 5 160 Routine inspections of stored fibres (see section 3.4) BarChip While stored 1 1 1 1

1.2 Stored fibres are exposed to UV degradation

Physical properties are reduced prior to usage of fibres 5 Improper storage

of fibres 2Visual inspection of fibres identifies chalking or other

physical flaws5 50 Store fibres as to minimise UV exposure

(see sections 3.4) BarChip While stored 1 1 1 1

1.3 Disposal of fibres not passing QC

High quantities of waste produced incurring disposal cost and airspace

consumption at landfill4 Manufacturing

techniques 2 Identified within manufacturing QC process 1 8

Adjust manufacturing techniques as necessary to minimise waste (see section

3.2)BarChip Manufacturing 3 1 1 3

1.4 Sourcing and manufacturing of raw material causing high emissions

Release of green house gasses 1Processing and

manufacturing of polymers

1 Air quality monitoring at manufacturing facility 1 1 Assess viability for the use of recycled

polymers BarChip Manufacturing 1 1 1 1

1.5 Waste generation in manufacturing facility during QC processes

Disposal of large quantities of fibres 4 Manufacturing techniques 4 Identified during manufacturing 1 16 Recycle fibres not passing QC (see

sections 4.2.3) BarChip Manufacturing 1 3 1 1

2 Transport (Section 3.3)

2.1 Fibres are lost from vehicle during transport Fibres pollute environment 6 Improper

packaging of fibres 2 Likely detected once received by distributor or contractor 9 108

Store and transport fibres in durable bags. Ensure bags are not damaged during

transport. (see sections 3.4)

BarChip, distributors,

transport companyPrior & during transport 3 1 2 6

2.2 UV degradationReduced strength of fibres and consequently concrete strength

reduced6

Fibres exposed to excessive UV during storage

1 N/A 1 6Packaging and add stabilisers to fibres. Store fibres out of direct sunlight. (see

sections 3.4)

BarChip, distributors, contractor

Manufacture to installation 1 1 1 1

2.3 Storage bag is punctured by fibres during transport Fibres pollute environment 6 Poor quality

packaging of fibres 3 Visual inspection before or during transport 5 90

Transport fibres in heavy duty bags. Undertake inspection of packaging prior

to transport. (see sections 3.4)BarChip, distributors Prior to transport 1 1 1 1

3 Construction (Section 3.6)

3.1 During spray application on dry land, fibres are liberated Fibres pollute environment 6

Wind, incorrect concrete mix, rain, unskilled

labour or incorrect application

5 Visual inspection during or following the spray process 8 240

Make effort to minimise rebound as per “Recommended practice: shotcreting in Australia”. Undertake inspection of work site following completion and clean up

rebound. (see section 3.7.1)

Installer of concrete

Rebound monitored during application with adjustments

taken where excessive rebound is identified final inspection

undertaken at the end of construction

2 2 1 4

3.2 Application in marineenvironment causes fibres to be washed into waterway

Pollution of waterways 9

Incoming tideover wet concrete excessive rebound or wasted concrete

8 Visual inspection during placement of cement 8 576

Control rebound. Where possible divert water. Undertake construction during

small tides and not before rainfall events. (see section 3.7.1)

Installer of concrete Before and during placement of cement 5 2 3 30

3.3 Incorrect dosage rates for fibres used

Concrete properties are lower than required - concrete service life

reduced7

Inaccurate measurement of

fibres3 Identified by weak concrete,

premature cracking or failure 7 147 Add premeasured bags or pucks (see section 3.5) Installer of concrete Immediately prior to placement 3 1 5 15

3.4 Fibres not evenly dispersed in concrete

Concrete not concrete properly reinforced 8 Inadequate/

improper mixing 2 Visual inspection of concrete prior to placement 2 32

Undertake concrete mixing as per manufactures guidelines (see sections

3.5)Installer of concrete During mixing 5 1 1 5

3.5 While stored at site, bags are broken

Fibres are blown by wind or rain, or are transported by fauna 6 Bag strength low,

bio- intrusion 3 Visual inspection by site personnel 4 72

Store fibres in durable bags. Appropriately store fibres at site. (see

sections 3.4)

BarChip, distributor, installer of concrete Prior to distribution 5 1 2 10

3.6 Wastage, due to over ordered concrete

Disposal of fibre reinforced concrete required 1 Over-ordering

concrete 8 Likely identified during construction 3 24 Ensure ordered concrete is as accurate

as possible Installer of concrete Before ordering 1 5 1 5

3.7 Fibres dropped during mixing process Fibres pollute environment 1 Lack of care during

mixing 4 Dropped fibres seen on ground 2 8 Take care not to allow fibres to be dropped (see section 3.5)

BarChip, installer of concrete During placement 1 2 1 2

3.8 Concrete segregation Pollution of environment with concrete and fibres 6

Release during various application

methods8 Wasted concrete seen on site 1 48 Clean-up waste. Minimise segregation of

concrete. (see sections 3.7) Installer of concrete Immediately after spill 1 5 1 5

Risk Priority Score

1-20

Very Low Risk. Unlikely.

21- 100

Low Risk.Possible.

100 - 250

Medium Risk.Likely.

251 +

Very High Risk.Probable.


1-2

Virtually no impact.Extremely low probability.

3-5

Very low impact.Very low probability.

6-10

Low Impact.Low Probability.

11-15

Medium Impact.Medium Probability.

16 +

High Impact.High Probability.

Probability Score







-10 High Impact)

A

Potential Cause



Probability

Detection Mode



probability) C


(RPN) 1 - 1000

A x B x C

Revised Severity A


B


CRPN

4 Service Life

4.1 Chemical degradationReduced strength of fibres and consequently concrete strength

reduced7

Fibres exposed to chemicals which cause premature

degradation

2Cracking or other signs of

reduced physical parameters visually identified

1 14 Identify non-compatible chemicals prior to use

BarChip, distributors, installer

of concrete

Prior to purchase of fibres, distributors to provide advice to installer of concrete. Contractors

to check SDS prior to use

6 1 1 6

4.2 Biological degradationReduced strength of fibres and consequently concrete strength

reduced7

Presence of polymer degrading micro- organisms



1 21Read SDS prior to selection of fibre,

monitor concrete for signs of premature degradation


of concretePrior to selection of fibres 6 1 1 6

4.3 Thermal DegradationReduced strength of fibres and consequently concrete strength

reduced7

Concrete exposed to high

temperatures3

Cracking or other signs of reduced physical parameters

visually identified3 63

Read PDS prior to selection of fibre, monitor temperature around concrete if

high temperatures expected



5 Disposal (Section 3.8)

5.1 Fibres dumped at landfill on tip face blown by wind Liberated fibres pollute environment 6

Fibres disposed of loosely

Placed with general waste

6 Fibres found outside of landfill site 6 216 Dispose of fibres in concealed package in

hazardous waste (see section 4.2)Installer of concrete,

landfill operator During disposal 5 1 3 15

5.2 Fibres placed on landfill washed into drainage system during rainfall events

Liberated fibres pollute environment 6 Fibres placed on top of general fill 3 Fibres found outside of landfill

site 6 108 Do not place fibres in location which they could be washed away (see section 3.7)

Installer of concrete, landfill operator During disposal 3 1 3 9

5.3 Fibres lost during transport to landfill site Liberated fibres pollute environment 6

Inadequate packaging of fibres

for transport4 Fibres seen blowing out of

vehicle or found near road 6 144 Securely package fibres prior to transport (see sections 3.4)

Installer of concrete/demolition

contractorDuring disposal 6 1 2 12

5.4 Animals consume or transport fibres from landfill

Death of animals, further spreading of fibres 8 Fibres left exposed

to environment 3 Fibres found outside of landfill site 4 96 Store fibres in bags preventing fauna

from accessing fibres. (see sections 3.4) Installer of concrete During disposal 2 1 1 2

6 Recycling (Section 3.8)

6.1 Fibre reinforced concrete not suitable for recycling crushing techniques

Higher cost of recycling material 6

Plastic fibres elongate instead of

snapping during crushing

8 Through operators of material recovery facility 10 480

Discuss viability of concreterecovery from fibre reinforced concrete. Practicality to implement broken fibre

recovery system. (see section 3.7)

BarChip, installer of concrete

Viability of recycling to be discussed with material recovery

facility3 2 1 6

6.2 Fibres lost during transport to recycling facility Liberated fibres pollute environment 6





contractorTransport 6 1 3 18

6.3 During concrete recycling, fibres are liberated from concrete

Fibres transported with surface runoff off-site 6

Concrete crushing causes fibres to be

liberated8 Fibres found outside of material

recovery facility 6 288Discuss risks with material recovery

facility operators. Implement broken fibre recovery system. (see section 3.7)

BarChip, distributor, installer of concrete, operator of material

recovery facility

Prior to disposal at material recovery facility 5 2 1 10






-10 High Impact)

A

Potential Cause



Probability

Detection Mode



probability) C


(RPN) 1 - 1000

A x B x C

Revised Severity A


B


CRPN

4 Service Life

4.1 Chemical degradationReduced strength of fibres and consequently concrete strength

reduced7

Fibres exposed to chemicals which cause premature

degradation



1 14 Identify non-compatible chemicals prior to use


of concrete

Prior to purchase of fibres, distributors to provide advice to installer of concrete. Contractors

to check SDS prior to use

6 1 1 6

4.2 Biological degradationReduced strength of fibres and consequently concrete strength

reduced7

Presence of polymer degrading micro- organisms



1 21Read SDS prior to selection of fibre,

monitor concrete for signs of premature degradation



4.3 Thermal DegradationReduced strength of fibres and consequently concrete strength

reduced7

Concrete exposed to high

temperatures3

Cracking or other signs of reduced physical parameters

visually identified3 63

Read PDS prior to selection of fibre, monitor temperature around concrete if

high temperatures expected



5 Disposal (Section 3.8)

5.1 Fibres dumped at landfill on tip face blown by wind Liberated fibres pollute environment 6

Fibres disposed of loosely

Placed with general waste

6 Fibres found outside of landfill site 6 216 Dispose of fibres in concealed package in

hazardous waste (see section 4.2)Installer of concrete,

landfill operator During disposal 5 1 3 15

5.2 Fibres placed on landfill washed into drainage system during rainfall events

Liberated fibres pollute environment 6 Fibres placed on top of general fill 3 Fibres found outside of landfill

site 6 108 Do not place fibres in location which they could be washed away (see section 3.7)

Installer of concrete, landfill operator During disposal 3 1 3 9

5.3 Fibres lost during transport to landfill site Liberated fibres pollute environment 6





contractorDuring disposal 6 1 2 12

5.4 Animals consume or transport fibres from landfill

Death of animals, further spreading of fibres 8 Fibres left exposed

to environment 3 Fibres found outside of landfill site 4 96 Store fibres in bags preventing fauna

from accessing fibres. (see sections 3.4) Installer of concrete During disposal 2 1 1 2

6 Recycling (Section 3.8)

6.1 Fibre reinforced concrete not suitable for recycling crushing techniques

Higher cost of recycling material 6

Plastic fibres elongate instead of

snapping during crushing

8 Through operators of material recovery facility 10 480

Discuss viability of concreterecovery from fibre reinforced concrete. Practicality to implement broken fibre

recovery system. (see section 3.7)

BarChip, installer of concrete

Viability of recycling to be discussed with material recovery

facility3 2 1 6

6.2 Fibres lost during transport to recycling facility Liberated fibres pollute environment 6





contractorTransport 6 1 3 18

6.3 During concrete recycling, fibres are liberated from concrete

Fibres transported with surface runoff off-site 6

Concrete crushing causes fibres to be

liberated8 Fibres found outside of material

recovery facility 6 288Discuss risks with material recovery

facility operators. Implement broken fibre recovery system. (see section 3.7)

BarChip, distributor, installer of concrete, operator of material

recovery facility

Prior to disposal at material recovery facility 5 2 1 10

Risk Priority Score

1-20

Very Low Risk. Unlikely.

21- 100

Low Risk.Possible.

100 - 250

Medium Risk.Likely.

251 +

High Risk.Probable.


Appendix C



Manufacturing (Section 3.2)

Pre-Manufacture (Section 3.1)

Distributors (Section 3.3)

Delivery of plastic granules to Manufacturing Facility (3.2 & 3.3)

Manufacturing of BarChip (3.2)

Transport (3.3)

Is waste recyclable?

Pallet (3.4)Do bags need to be

separated from pallet?

Repackage securely (3.4)

Can fibres be repackaged or used?

Delivery/transport (3.3)

Loose/spilt fibres (3.4)

Repackage securely (3.4)

Is product suitable for delivery?

Y

Y

Y

N

N

N YN

Can Material Be recycled?

N

Landfill(4.2.1)

Recycle(4.2.3)

Y

Material Extraction (3.1)

Recycled material (4.2.3)

Landfill(4.2.1)

Suppliers/Customers

NOTE: Numbers in brackets refer to relevant sections in "Environmental Management of BarChip" (ATCW, 2016)

Appendix C1

NOTE: Numbers in brackets refer to relevant sections in “BarChip Environmental Management Plan”


Tunnelling (Section 3.7.1)

Excess Fibres (4.1)

Is there spilt concrete?

Clean-up and Disposal of Concrete/BarChip (3.7)


Site clean up inc. tools, wheel barrows etc.. (3.7)

Can tools be washed without release of

BarChip?

Wash tools (3.7)

Remove BarChip from control measures (3.7)

Install Control Measures (3.7)

Storage Onsite (3.4)

Y N

Mixing (3.5)

Can Fibres be used elsewhere?

Y N

Y

N

Y N

Landfill(4.2.1)

Recycle(4.2.3)

Casting or Spraying (3.7)

Delivery/Transport(3.3)

Appendix C2Tunnelling (Section 3.7)



Marine

(Section 3.7 & 4.2.2)

Excess Fibres (4.1)


Can Materials Be recycled?

Can tools be washed without release of BarChip?

Wash tools (4.1)

Remove BarChip from control Install Control Measures (3.7)

Storage of fibres (3.4)

Y N

Mixing (3.5)

Can fibres be used elsewhere? Y N

Casting or Spraying (3.7)

Y

N

Y N

Could fibres become inundated with water?

YN


Move and repackage as necessary (3.3 &

3.4)

Site clean up inc. tools, wheel barrows etc.. (3.7)

Landfill(4.2.1)

Recycle(4.2.3)

Delivery/Transport(3.3)

Appendix C3


Precast (Section 3.7.3)

Landfill(4.2.1)

Repackaging of excessFibres (3.4)

Is there spilt concrete?Clean-up and disposal of Concrete/BarChip (3.7)

Can waste be recycled?

Site Clean up inc. tools, wheel barrows etc.. in wash bay

(4.1)

Remove BarChip from control measures (3.7)

Storage of fibers onsite (3.4 & 4.2)

Mixing (3.5)

N

Casting or Spraying

Y

Y N

Are permanent waste collection systems operational?

Rectify (4.1)

Y N

Recycle(4.2.3)

Delivery/Transport


Appendix C4



Commercial and Industrial Floors (Section 3.7.2)

Repackaging of ExcessFibres (3.4 & 4.2)


Clean-up and disposal of Concrete/BarChip (3.8)

Can waste be recycled?

Site clean up inc. tools, wheel barrows etc.. in

wash bay (4.6)

Remove BarChip from sediment traps (4.1)

Storage of fibres onsite (3.4)

Mixing (3.5)

NY

Y N

Are permanent waste collection systems

operational?

Rectify (4.7)

Y

N

Delivery of concrete (3.6)

Are sediment appropriate sediment controls installed?

Install sediment controls (3.7) YN




Site Clean upinc. tools, wheel barrows etc.

(3.7)

Can tools be washed without release of BarChip?

Install Control Measures (3.7)

N

Casting (3.7.2)

Y N

Y

Y N

Landfill

Recycle(4.2.3)

Delivery/Transport


Appendix C5



Demolition of BarChip

Reinforced Concrete (Section 4.2)

Is transportation tomaterial recovery facility

feasible?

Demolition of Structure (4)

Are there loose fibres?


Landfill(4.2.1)

Recycle(4.2.3)

N

Y

N

Will demolition result in loose fibres (e.g. from broken

concrete)

Y N

Install control measures (3..7)

Can loose fibres be readilyrecovered?

N

Y

Y N

Recover fibres (3.7)

Y

Could fibres be released during

transit?Y

Install control measures (3.7)

N

Construction Site/Application Area


Appendix C6



Material Recovery Facility (Section 4.2.3)


Landfill(4.2.1)

Recycle

YN

Crush concrete (4.2.3) Usable aggregate

Will crushing concrete result in loss of fibres?

N Install control measures (3.7)

Can loose fibres be readilyrecovered?

N

Y

Recover loose fibres (3.7)

Y



Appendix C7



Recycling of Materials (Section 4.2.3)

Can material be used for fill?

Can material be used onsite?

Landfill(4.2.1)

Send to recycling

facility (4.2.3)N

Y

N

Y N

Could fibres become liberated and pollute environment?

Are material clean and separated from other wastes?

Y

N

Use onsite (4.2.2)

Can this be avoided?

Implement control measures (3.7)

Y

N

Could fibres become liberated and pollute

environment?

Y

N

Use as fill (4.2.2)

Can this be avoided?

Implement control measures (3.7)

Y

N

Y



Appendix C8



Landfill Disposal (Section 4.2.1)

Can BarChip be recovered from

stormwater capture

Install controls (3.7)

Could BarChip be released with water or wind?

Y

N

Add soil cover for water and wind protection (4.2.1)

Y

N

Dispose of BarChip in Landfill (4.2.1)

Install controls (3.7)



Appendix C9



BarChip is committed to produce zero waste and to

ensure that no BarChip products enter or adversely affect land

and marine environments. BarChip is working closely with all parties involved to achieve

this goal.

OUR VISIONWe believe that long term

business relationships can only be sustained by a commitment to provide the highest quality

products and services. We make sure to understand your

concrete, know the performance requirements and work with you

to get the right design and the right performance outcomes.

OUR PROCESSWhen you work with BarChip you know that your concrete

asset has been reinforced to the latest engineering standards. It will never suffer from corrosion. It will be cheaper and quicker to build. It will be safer and it will

keep performing throughout its entire design life.

YOUR PRODUCT

BarChip Inc.

Disclaimer: This information has been provided as a guide to performance only, for specific and supervised conditions. The user is advised to undertake their own evaluation and use the services of professionals to determine the product suitability for any particular project or application prior to commercial use. ISO 9001:2008. EMP_2018_1. © BarChip Inc. 2018

Distributors are located in other regions. For contact details visit www.barchip.com.

BarChip Inc. [email protected]: +61 1300 131 158 N. America: +1 704 843 8401

EMEA: +353 (0) 1 469 3197Asia: +65 6835 7716S.America: +56 2 2703 1563Brazil: +55 19 3722 2199

www.barch ip.com

Documents

Fiber Reinforced Concrete - BarChip Environmental Management … · 2019-01-14 · 100% of underground mining operations in Australia had switched from steel to synthetic fibre reinforcement