IGS Magazine Spring 2022: Decarbonising the Glass Industry by IGS Magazine

Building tomorrow with carbon-neutral silicones Design for sustainability with the first-ever carbon-neutral silicones for structural glazing, insulating glass and weathersealing on building façades. Audited per the recognized PAS 2060 standard, Dow offers a project-specific service to

ALITY

building’s environmental impact and enhance

E RBON N

This innovative service can help you decrease a

FAÇADES

VERIFIE

help you secure veriﬁed carbon-neutrality certiﬁcates.

S 2060 PA

green-building ratings. Designing with more freedom by engineering less impact.

dow.com/carbonneutralsilicones Images: GettyImages-80193891, dow_41027741144 NOTICE: No freedom from infringement of any patent owned by Dow or others is to be inferred. The product shown in this literature may not be available for sale and/or available in all geographies where Dow is represented. The claims made may not have been approved for use in all countries. Dow assumes no obligation or liability for the information in this document. References to “Dow” or the “Company” mean the Dow legal entity selling the products to Customer unless otherwise expressly noted. NO WARRANTIES ARE GIVEN; ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY EXCLUDED. ®™ Trademark of The Dow Chemical Company (“Dow”) or an aﬃliated company of Dow. © 2022 The Dow Chemical Company. All rights reserved. #16649D Form No. 63-7183-01 0222

IGS MAGAZINE’S PUBLISHING PARTNER 2022

For more information on our Publishing Partnership, contact lewis@igsmag.com intelligent glass solutions | spring 2022

PUBLISHER’S WORD

LESS TALK, MORE ACTION! T

he path is clear, the future is not! These words, emboldened on the front cover of our Spring Edition, reflect a concerning reality that is confronting humankind and our planet. While the climate crisis has been a pressing topic for many years, there is a palpable and renewed sense of urgency that has emerged since the UN COP26 conference in November of 2021. Driven by the Paris Agreement and ambitious policies such as the Green Deal and the European Union’s ‘fit for 55 package’, both the public and private sectors have laid out clear paths in the transition to a sustainable, low-carbon, circular economy. However, while these advances and progressive ideals look good on paper, the fact is, we

need to put policy into practice. The onus is on governments, private companies and individuals to follow through on the ‘talk’, to refrain from greenwashing and to take action. Indeed, this will be the primary focus of the Glass Supper’s Panel discussion in May. “Architectural Glass: Delivering on a net-zero economy” will see charismatic leaders, including James O’Callaghan (Eckersley O’Callaghan), Klaus Lother (Permasteelisa), Jean-Paul Hautekeer (Dow), Giles Martin (WilkinsonEyre), David Entwistle (Saint-Gobain) and Anders Hall (ES-SO) take centre stage and cast a critical eye over the industry and state-of-play. In my line of work, I often get the unique opportunity to talk with industry professionals

intelligent glass solutions | spring 2022

and listen, first hand, to the central issues and current thoughts on how the glass and wider construction industry should respond. While I am ever the optimist, the truth of the matter is that I am often overwhelmed by the far-reaching nature of the problems and the ever-complex web of solutions that need to be put in place, if we are to meet ambitious climate goals. From these meetings, perhaps one of the most crucial whisperings is that the ‘business as usual’ approach, even if improved, will not deliver the necessary savings. What is required is a seismic shift of culture in the world of architecture and construction which will involve all players in the chain. As Gianluca Rapone says “we need to question every choice we used to make with the old model, and adopt a new attitude where

PUBLISHER’S WORD

“The world is reaching the tipping point beyond which climate change may become irreversible. If this happens, we risk denying present and future generations the right to a healthy and sustainable planet – the whole of humanity stands to lose” - Kofi Annan, Former Secretary-General of UN

carbon is at the centre of every decision”. It is with this firmly in mind, that we bring you the opening issue of 2022 where we explore the individuals and companies relentlessly driving the decarbonisation of our industry. From galvanising circularity in glass to recycling, adaptive reuse, sustainable glass technologies, advances in alternative carbon neutral fuels in production, as well as requirements for modern façades, which improve the CO2-neutrality of buildings, discover the pioneers already driving this change. Our eternal gratitude goes to those who sacrificed much of their

valuable time spending hours preparing articles exclusively for all the beautiful men and women who read IGS - Thank you! Should you wish to address the industry in 2022, please feel free to contact me for a more personal and tailored discussion at your earliest convenience. This is IGS, the world’s most popular and beloved glass industry magazine. Nothing more, nothing less.... nothing else!

Lewis Wilson Marketing Director and Editor for IGS Magazine Email: lewis@igsmag.com

intelligent glass solutions | spring 2022

CONTENTS IGS SPRING EDITION 2022 E X E C U T I V E B OA R DRO O M C O M M E N TA RY 8

DECARBONIZE NOW! THE NEXT FRONTIER IN GLASS FAÇADE INNOVATION Laura Karnath - Senior Associate and Senior Enclosure Technical Designer, Walter P Moore and Sophie Pennetier - Associate Director, Special Projects, Enclos Addressing the costs of carbon through the life cycle of buildings, from manufacturing, transportation, use, and less tangible social costs.

ACHIEVING A VIRTUOUS CIRCLE: DRIVING CIRCULARITY IN THE GLASS INDUSTRY Graham Coult - Technical Director, Eckersley O’Callaghan and Rebecca Hartwell - Cambridge University, Research Partner Galvanising circularity in flat glass through collaboration and cross-disciplinary innovation.

CARBON-LED FAÇADE DESIGN Gianluca Rapone - Associate and Sustainability Lead, FMDC Gianluca envisions what it will take to design façades with carbon saving as the main driver.

DESIGN AND ENGINEER WITH LESS IMPACT: CARBON NEUTRAL SILICONES IN FAÇADES – A WINDOW OF OPPORTUNITY Valérie Hayez - Global Façade Engineering & Architectural Design Engineer, High Performance Building Solutions, Dow and Jayrold Bautista - Associate TS&D Scientist, Dow Building tomorrow with carbon neutral silicones: a blueprint to material efficiency, carbon offsetting, resuse and reductions in embodied and operational carbon.

28 42

REFLECTIONS FROM THE UN I N T E R NAT I O NA L Y E A R O F G L A S S 2 0 2 2 52

FLAT GLASS: LEADING THE SUSTAINABILITY RACE Inspired by a speech given by Mr. Philippe Bastien, Chairman, Glass for Europe at the Palace of Nations in Geneve Seizing the chance to trigger the much-needed virtuous cycle of decarbonization. Glass is clearly on track today. But what about tomorrow?

DEVELOPMENT AND TRENDS OF GLASS INNOVATION UNDER GLOBAL CLIMATE CHANGE Prof. Peng Shou - Chief Engineer, China National Building Material Group and Board Chairman, China Triumph International Engineering Co., Ltd Embracing low-carbon development strategies – from core to key and foundational technologies in glass.

REFLECTIONS ON REFLECTION: GLASS IN ARCHITECTURE Sol Camacho – Founder and Director, RADDAR From historical to contemporary typologies, glass has always solved the challenges of the day. Step into the glass time machine and explore its significant rise to prominence.

52 42 62

8 4

intelligent glass solutions | spring 2022

T R A N S PA R E N T A R C H I T E C T U R A L STRUCTURES

S US TA I NA B L E T E C H N O L O G I E S AND TRENDS GAINING TRACTION

A POWERFUL COMBINATION: GLASS AND MODULAR TIMBER Okalux Symbolism and function merge with glass and modular timber as daylight drives the design of the Lily-Braun-Gymnasium façade in Spandau.

THE NEW JEWEL IN THE CROWN OF DUBLIN Andreas Scheib - Chief Communication Officer, Glas Trösch Group Explore the striking façade of Spencer Place, a unique and sustainable glass veil second-skin in the heart of Dublin

NET-POSITIVE GLASS BUILDINGS OF THE FUTURE Amber Gupta - Accredited Professional, Onyx Solar Energy Sustainable energy-producing structures of tomorrow and the breakthrough building material that’s making it happen today

106 FLEXIBLE SPACERS: MORE EFFICIENCY IN THE MANUFACTURING OF INSULATING GLASS Christoph Rubel - European Technical Manager, Edgetech Europe A deep dive into the sustainability and efficiency benefits of flexible insulating glass spacer systems with exemplary case studies from Edgetech’s portfolio. 130 DECARBONISING THE GLASS INDUSTRY AND BUILT ENVIRONMENT: A GLOBAL INDUSTRY IN NEED OF LOCAL SOLUTIONS Aston Fuller - General Manager, Glass Futures Exclusive access to the mold-breaking Glass Futures and their research into low carbon alternative fuels for glass furnaces. 130 THE FUTURE OF GLASS MELTING: REDUCING CARBON EMISSIONS Erik Muijsenberg – Vice President, Glass Service Inc. A dark glass factory may be difficult to imagine by 2030, but not by 2050 when the light from hot gobs falling from the forehearth spout will be all that illuminates the factory hall. 140 WE CAN’T AFFORD TO JUST BUILD GREENER, WE MUST BUILD LESS Johannes Novy - Senior Lecturer in Urban Planning, School of Architecture and Cities, University of Westminster Johannes begs the question: is building greener really the solution?

78 Intelligent Glass Solutions

D E C A R B O N I S I N G

T H E

G L A S S

I N D U S T R Y

THE PATH IS CLEAR, THE FUTURE IS NOT.

Spring 2022

Spring 2022 www.igsmag.com

An IPL magazine

Image: Climate Crisis Image courtesy: Oleksandrum on Adobe Stock Intelligent Glass Solutions is Published by Intelligent Publications Limited (IPL) ISSN: 1742-2396 Publisher: Nick Beaumont Accounts: Jamie Quy

146 THE ‘GLASS WORD’: IGS INTERVIEWS KLAUS LOTHER Klaus Lother - CEO, Permasteelisa Group Unfiltered access into the brilliant mind of the CEO steering one of the worlds most prolific façade design and engineering firms.

Editor: Lewis Wilson Production Manager: Kath James Director of International Business Network Development: Roland Philip Manager of International Business Network Development: Maria Jasiewicz Marketing Director: Lewis Wilson

Page Design Advisor: Arima Regis Design and Layout in the UK: Simon Smith Intelligent Glass Solutions is a quarterly publication. The annual subscription rates are £79 (UK) , £89 (Ireland & Mainland Europe), & £99 (Rest of the World) Email: nick@intelligentpublications.com

Published by: Intelligent Publications Limited, 3rd Floor, Omnibus House, 39-41 North Road, London N7 9DP, United Kingdom Tel: +44 (0) 7703 487744 Email: nick@intelligentpublications.com www.igsmag.com

The entire content of this publication is protected by copyright. All rights reserved. None of the content in this publication can be reproduced, stored or transmitted in any form, without permission, in writing, from the copyright owner. Every effort has been made to ensure the accuracy of the information in this publication, however the publisher does not accept any liability for ommissions or inaccuracies. Authors’ views are not necessarily endorsed by the publisher.

intelligent glass solutions | spring 2022

Inside th Klaus Lother

CEO, Permasteelisa Group has The Glass Word Page 146 “It is this holistic approach to decarbonisation, one that encompasses the entire supply chain, all project stakeholders and end users, that I believe is necessary if we are to make significant strides towards achieving the ambitious targets” SOPHIE PENNETIER Associate Director Special Projects, Enclos Decarbonization is the foremost challenge facing the building industry, and one for which we do not have perfect or easy solutions. The costs of carbon through the life cycle of buildings, from manufacturing, transportation, use, and less tangible social costs, are of paramount concern and must be addressed. Page 8

GRAHAM COULT Technical Director, Eckersley O’Callaghan This is a call to arms to both the glass world and the wider construction industry. We need to raise awareness of what can be done to drive greater circularity by joining together across the sector in a spirit of crossdisciplinary innovation. Only then can we bring about the much-needed changes required. Page 19

RECONCI

intelligent glass solutions | spring 2022

his Issue GIANLUCA RAPONE Associate, FMDC We should expect shifts in clients’ expectations and in public perception, new economic and business models, a deep re-think of the way we design, procure, build, occupy, and decommission buildings. Essentially a change of culture in the world of architecture and construction which will involve pretty much every aspect. Page 28

VALÉRIE HAYEZ Global Façade Engineering & Architectural Design Engineer, High Performance Building Solutions, Dow Carbon targets will increasingly be required for planning permission with clients taking a more active role in developing a brief for commissioning their carbon measurements. Reductions in operational carbon - or from the energy used to power, heat and cool a building, have been tackled through energy efficiency measures and are where policymakers, developers, architects and engineers have made significant advances. Page 40

PROF. PENG SHOU Chief Engineer, China National Building Material Group and Board Chairman, China Triumph International Engineering Co China aims to peak its carbon dioxide emissions by 2030 and strives to achieve carbon neutrality by 2060. Glass plays an important role as a unique functional material in promoting this energy transition and low-carbon transformation. Page 62

JOHANNES NOVY Senior Lecturer in Urban Planning, School of Architecture and Cities, University of Westminster This is the industry’s inconvenient truth. The climate crisis is, in no small part, a product of our voracious appetite to build. It is not something, as climate activist Greta Thunberg has pointed out, that we can simply build our way out of. We cannot afford to only build greener. We need to build less. Page 140

ILIATION

with nature intelligent glass solutions | spring 2022

EXECUTIVE BOARDROOM COMMENTARY

DECARBONIZ

THE NEXT FRONTIER IN GLASS F

Walter P Moore and Enclos have worked together on several projects, including the LEED Gold Chase Center in San Francisco, California. Their collaboration on today's high-performance projects has inspired ideas about the future of design assist and bidding. Photo: Jason O'Rear | Golden State Warriors

intelligent glass solutions | spring 2022

EXECUTIVE BOARDROOM COMMENTARY

ZE NOW!

FACADE INNOVATION

Laura Karnath, AIA, NCARB, Senior Associate and Senior Enclosure Technical Designer, Walter P Moore and Sophie Pennetier, Associate Director, Special Projects, Enclos

Addressing the costs of carbon through the life cycle of buildings, from manufacturing, transportation, use, and less tangible social costs

intelligent glass solutions | spring 2022

EXECUTIVE BOARDROOM COMMENTARY

n search of natural daylight, views, and enhanced performance, architectural glass has a long history of driving innovation in construction. Today the greatest challenge facing the building industry is the climate crisis. It is well known among building industry professionals that buildings are responsible for approximately 40 percent of global carbon emissions. There are two types of building-related carbon emissions we must consider: operational carbon and embodied carbon. Operational carbon emissions correspond to the building’s energy use throughout its entire life and represent 28 percent of global carbon emissions, according to the Carbon Leadership Forum. Embodied carbon emissions, representing approximately 11 percent of global carbon emissions, are the emissions associated with building materials and construction: from the extraction and processing of raw materials to manufacturing, transportation, and installation on site (see Fig. 1). These emissions occur up front, before a building is even occupied. Tackling embodied carbon emissions is crucial to meeting the near-term climate goals set forth in the Paris Agreement.

The building industry as a whole and the architectural glazing industry in particular have been markedly successful at reducing operational carbon emissions through improvements in insulated glass units and low-e coatings. There is still much progress to be made, however, on reducing and eventually eliminating embodied carbon emissions associated with the production of facade materials, including glass, aluminum, gaskets, and sealants. We believe supply chain decarbonization is the next frontier of innovation in architectural glass. Drivers of Embodied Carbon To understand embodied carbon, we need to understand supply chains and manufacturing processes. Designers should ask themselves: “How and where are the materials I am specifying made?” The power sources used in manufacturing, including both power purchased from the local grid and on-site fuel combustion, have a substantial impact on embodied carbon of building products. Norsk Hydro and the NSG Group are two manufacturers who are leading the charge in decarbonizing materials

Fig. 1: Source: Carbon Leadership Forum

intelligent glass solutions | spring 2022

used in glazed facades. The NSG Group recently announced they conducted a successful trial of hydrogen power in one of their float lines, which if implemented at scale could dramatically reduce the carbon emissions of glass production. Norsk Hydro currently offers low carbon aluminum with a global warming potential (GWP) of only 4kgCO2eq per kg of aluminum, which they claim is approximately one quarter of the industry average emissions. They achieve carbon reductions through the use of renewable energy at their Norwegian smelters and recycling of postconsumer aluminum, using much less energy than the production of primary aluminum. They aspire to deliver commercial quantities of near-zero carbon aluminum in 2022, with a GWP below 1kgCO2eq per kg of aluminum, and to achieve net-zero aluminum by 2030. Sourcing materials from low-carbon manufacturers seems ideal, but is not yet available at scale and might not match the client’s budgets and schedules. Design and construction teams will have to explore other options for carbon reduction while these technologies are scaling up. Beyond manufacturing, the emissions from transportation, especially in the U.S. market, cannot be ignored. Research by Isabelle Hens in collaboration with Sophie Pennetier and Simon Schleicher, to be published at the next Facade Tectonics 2022 World Congress, shows GWP variations in the range of +/- 5 to 15 percent for the few supply chain options considered. It is important to note that this was a specific benchmark study, and not necessarily representative of systems outside of the context of the study, but it gives us a window into transportation impacts. Curtain wall supply chains are complex, and design decisions can have unexpected impacts on embodied carbon due to this complexity. Unknown to most designers, choice of location for aluminum extrusion is driven primarily by finish, then length and profile width (die diameter). The location of assembly is driven by a number of factors, such as: economics, labor rates, trucking distances, and more. The same factors apply to the glass supply chain. Glass may be produced in one location, coated in another, fabricated into an IGU in a third, and the IGU installed in a curtain wall unit in a fourth, with each step requiring potentially hundreds of miles of transit between locations (see Figs. 2 & 3). All these steps happen before the glass is even transported to the construction site for installation.

EXECUTIVE BOARDROOM COMMENTARY

Fig. 2: Map of glass manufacturers and fabricators in North America

Fig. 3: Sample of U.S. curtain wall supply chain (three scenarios)

intelligent glass solutions | spring 2022

EXECUTIVE BOARDROOM COMMENTARY

This fragmentation of curtain wall production has increased as shops have become more specialized, and owners’ budgets have become increasingly aggressive in the context of a global market. Transportation between facilities may require trucking, which is highly carbonintensive transportation. The North American market is most affected by this challenge, where distances are greater than in places like Europe, and where road transportation has limited alternatives. It is important to note that transportation method matters as much as transportation distance. Walter P Moore’s 2020 stewardship report, Embodied Carbon, A Clearer View of Carbon Emissions, deconstructed the impacts of different transportation methods. Its findings showed each mile of truck transport to emit nearly four times as much carbon as barge transport, when transporting the same amount of material the same distance. Thus, manufacturers in regions with better access to transportation by waterways and rail are likely to have lower transportation emissions. Where rail and water transportation are not available, transportation decarbonization is possible

through electrification of trucking. California is pushing for decarbonization of trucking, and will require increasing percentages of truck sales in the state to be zero emissions vehicles starting in 2024. Transportation impacts are even greater towards the later stages of manufacturing when trucks are “shipping a lot of air” after elements have been assembled. Many manufacturers have optimized trucking by shipping some parts “KD” (Knocked Down), to be assembled on site. This approach is common for large sunshades, but yields greater installation times. It is also at odds with some virtues of unitized facades and can be a significant upcost in high-market cities. Carbon Informed Design Assist Due to the complexity of material procurement and manufacturing, combined with factors that influence a design, the only way to fully understand the available opportunities to reduce embodied carbon is through transparency and collaboration. Design Assist is a highly collaborative process in which the owner engages the construction team to assist

the architect during the design phase. The goal of a traditional Design Assist process is to reduce cost, accelerate the schedule, and improve the curtain wall design by providing early constructability feedback and advice on material cost and availability. We propose taking this collaborative approach to the next level by leveraging the expertise of the contractor and curtain wall fabricator to optimize the curtain wall for embodied carbon reduction through a Carbon-Informed Design Assist process. This process enables every stakeholder to understand the environmental impacts of design and procurement decisions early enough to have a real impact. As a Design Assist partner, a contractor can provide insight into the complexity of supply chains and drivers of carbon emissions that designers may not have access to, and through a Carbon Informed Design Assist process can suggest simple changes which could dramatically reduce embodied carbon emissions associated with the facade. For example, they can notify the design team and client when a design decision triggers carbonArchitectural glass may be produced in one location, coated in another, and fabricated into an IGU in a third location. There may be hundreds of miles between each of these locations and the building site. Photo: Jason O'Rear | Golden State Warriors

intelligent glass solutions | spring 2022

EXECUTIVE BOARDROOM COMMENTARY

Supply chain decarbonization is the future of innovation in architectural glass. Photo: Jason O'Rear | Golden State Warriors

intensive supply chains. Currently, the bigger aluminum extrusion presses used for curtain wall mullions, shading fins, and other aluminum features larger than 16 in. (typically) are located outside the U.S., while 12 in. presses are still rare across the U.S. While the die diameter threshold is ever evolving, a continued dialog between parties should identify when a design change yields a supply chain change. The same logic applies to maximum lengths and weights for finishing lines for painting and anodizing tanks. Typically, smaller parts are available from a wider range of suppliers and there are likely to be more local options. These factors can all be considered through an optioneering process, which designers are especially well-positioned to take on. By the time a bid is out, it is typically too late for the manufacturers to make any substantial change to reduce environmental impacts. Designers

are accustomed to using computational tools to iterate through multiple options throughout the design process, taking a diverse array of factors into account. Traditionally, this process has been used to define and rationalize complex geometry for constructability and to enable more efficient design coordination. We propose re-deploying the computational tools, skill sets, and workflows design firms have at their fingertips in service of developing low-carbon design solutions. The best results can only be achieved if the right information is available when design and procurement decisions are being made. Vital to this process are transparency, collaboration, and shared commitment to a common goal of delivering the lowest carbon projects possible. Key information from the contractor, when provided at the right time, can be integrated back into the computational design and optimization process.

Holistic Bidding Holistic bidding is a departure from the typical combination of Budget + Schedule + Specifications. It is a transparent evaluation process, adding criteria beyond industry standards but not necessarily connected to a points system like LEED (which is typically not considered during the bidding process). In the table in Fig. 4 (adapted from a matrix designed to evaluate embodied carbon in concrete mix designs) several wall systems are evaluated based on cost and carbon in the context of an example project. It is important for all stakeholders involved to understand the importance of considering each system cost in a specific project context, as factors like local labor rates, project schedules, and others can be variable. Within the U.S. the same curtain wall system may have different unit costs from place to place. (Note: the costs included in this example are for illustration only and do not reflect a real project.)

intelligent glass solutions | spring 2022

EXECUTIVE BOARDROOM COMMENTARY

Design Team Estimate/Target/Cap

Wall Type

Area

EWS-1 EWS-2 EWS-3 EWS-4

4,000 2,000 7,000 8,000

GWP [kgCO2/ Total GWP u_cost

[sf]

m2]

[kgCO2]

[$/sf]

180 160 100 130

720,000 320,000 700,000 1,040,000

175 200 300 250

TOTAL COST GWP REDUCTION

2,780,000

Supplier BASE Bid

Projected Lead Time [weeks] Cost $700,000 12 $400,000 16 $2,100,000 18 $2,000,000 20

GWP

Total GWP

u_cost [$/sf]

Cost

Lead Time [weeks]

[kgCO2/m2]

GWP

Total GWP

u_cost [$/sf]

Cost

Lead Time

155 180 80 150

620,000 360,000 560,000 1,200,000

190 210 260 110

$760,000 $420,000 $1,820,000 $880,000

12 16 18 20

130 190 80 110

520,000 380,000 560,000 880,000

200 185 310 270

$800,000 $370,000 $2,170,000 $2,160,000

16 16 20 12

[kgCO2/m2]

$ 5,200,000

Supplier Low Carbon ALTERNATE

[kgCO2]

2,740,000 -1%

$ 3,880,000 -25%

[kgCO2]

2,340,000 -16%

[weeks]

$ 5,500,000 8%

Fig. 4: Holistic bidding comparative table example

𝑓𝑓(𝑥𝑥) = '

𝑓𝑓(𝑥𝑥)

((𝐺𝐺𝐺𝐺𝐺𝐺!,# )$ + (𝐺𝐺𝐺𝐺𝐺𝐺!,# − 𝐺𝐺𝐺𝐺𝐺𝐺%#&,# )' + (𝐺𝐺𝐺𝐺𝐺𝐺!,# − 𝐺𝐺𝐺𝐺𝐺𝐺!,#() )* + (𝐷𝐷)+ + (𝐸𝐸), 0

: Carbon evaluation parameter value, unitless

a, b, c, d, e: factors at the discretion of the bidding team

𝐺𝐺𝐺𝐺𝐺𝐺!,# : GWP of supplier A, at year N, reflects the supplier’s system current GWP 𝐺𝐺𝐺𝐺𝐺𝐺!,#$% : GWP of supplier A, at year N-3, reflects the supplier’s system GWP 3* years ago 𝐺𝐺𝐺𝐺𝐺𝐺&#',# : GWP of industry, at year N, reflects the supplier’s industry system current GWP (𝐺𝐺𝐺𝐺𝐺𝐺!,# − 𝐺𝐺𝐺𝐺𝐺𝐺&#',# )( : current carbon competitiveness of the supplier vs. the industry (𝐺𝐺𝐺𝐺𝐺𝐺!,# − 𝐺𝐺𝐺𝐺𝐺𝐺!,#$% )( : current carbon improvement of the supplier over the past 3* years 𝐷𝐷 : represents the positive impact of investments over the past 3 years towards decarbonization (covers equipment capital, research and development, etc.) 𝐸𝐸 : other factors to be defined, such as project-specific carbon innovation * 3 years for illustrative purposes only, at the discretion of the bidding team

Fig. 5: Concept for embodied carbon rating equation

With increased demand for faster turnaround times during the post-lockdown economic recovery, contractors and manufacturers will also need further improvement of the bidding process in order to free up resources to evaluate low-carbon supply chain options. For instance, in the U.S. market, still too few projects leverage BIM as the central bidding platform. The ideal solution is to incorporate into the bidding platform the necessary framework to quantify the project more completely, query the model to extract relevant data, and produce accurate estimates of embodied carbon. This means using live schedules and 3D information with embedded attributes, in lieu of PDFs and stripped-down models shared via underfeatured cloud platforms. The AEC industry in the U.S. could tie LOD standards to specific project stages for better bidding. Often, BIM data used during bid is broken, outdated, and/ or inconsistent. Further, the offline RFI process is often insufficient at addressing issues for manufacturers to timely and accurately explore and price complex projects. In other words, in order to provide meaningful feedback to 14

designers, not just on price but also on carbon, contractors need better data. Building upon the table proposed in Fig. 4, Holistic Bidding could potentially include a rating of each system, such as proposed in the formula in Fig. 5, with factors and data points (or absence thereof) at the discretion of the owner and designer. Why and How to Incentivize Holistic Bidding? To incentivize Carbon-Informed Design Assist and Holistic Bidding, the industry needs a framework to understand how to factor carbon into the decision-making process. Because there is not yet a robust policy framework governing the entire North American market, we need to look at other options. There are several mechanisms available to us, through both voluntary measures and policy. Here we will divide them into two broad categories: carbon pricing and carbon limits. On the pricing side, one possible mechanism

intelligent glass solutions | spring 2022

is to apply a “social cost of carbon” (SCC). The social cost of greenhouse gasses is a tool developed by the U.S. government, combining climate science and economics to estimate the cost in dollars of the long-term damage done by today's greenhouse gas emissions. These estimates include the costs associated with climate change-driven events such as wildfires, floods, and storms, and their impacts on communities. Converting the negative effects of carbon emissions into dollars makes it easier to incorporate carbon emissions into the decision-making process. Unfortunately, there is not a single agreed-upon number for the social cost of carbon. This is due to uncertainty in estimating future impacts, and different discount rates used in various models (see Fig. 6). Currently, the widely accepted calculation for the social cost of carbon in the U.S. uses a 3 percent discount rate, placing the social cost of 2022 carbon emissions at $53 per ton. However, an alternative model designed to capture the damages associated with extreme outcomes

EXECUTIVE BOARDROOM COMMENTARY

Discount Rate and Statistic GWP

Emissions Year

5% Average

3% Average

2.5% Average

3% 95th Percentile

2020

152

Type

2025

169

Curtain Wall System A

2030

187

2035

206

2040

103

225

2045

110

2050

116

Fig. 6: Social cost of carbon

Social Cost of Carbon Emissions in 2022 [USD/m2] 3% Average

2.5% Average

3% 95th Percentile

$53

$79

$159

111

$5.90

$8.78

$17.69

Curtain Wall System B

136

$7.21

$10.72

$21.60

Curtain Wall System C

166

$8.80

$13.08

$26.36

242

Curtain Wall System D

180

$9.54

$14.18

$28.58

260

Curtain Wall System E

188

$9.96

$14.81

$29.85

Curtain Wall System F

204

$10.81

$16.08

$32.40

[kgCO2eq /m2]

Fig. 7: Comparison of six example curtain wall systems with their GWP values and associated social cost of carbon under three SCC models

Carbon caps for specific building materials are a promising avenue for the future of emissions reduction Photo: Jason O'Rear | Golden State Warriors

places it as high as $159, and these values will increase every year. The table in Fig. 7 shows GWP values per square meter of several different curtain wall systems, along with their associated social cost of carbon. We observe that the current recognized SCC value does not add substantially to the unit cost of a typical curtain wall system, depending on the model used, however, it does provide a framework for factoring carbon emissions directly into pricing. In the absence of a policy governing this, owners, designers, and contractors can decide what model they want to use for pricing carbon.

Many companies now use an internal carbon pricing scheme to inform their decision-making around emissions reduction. Some companies in the AEC industry are making voluntary commitments to purchase offsets for estimated carbon impacts of each project. To do this, design and construction teams would use life-cycle assessment to estimate the embodied carbon emissions associated with a given project, and then purchase high quality carbon offsets. Simply buying offsets without reducing emissions is not enough to reach climate goals, however. The purpose of committing to purchasing offsets is twofold: to mitigate the

effects of unavoidable emissions, and to create a financial incentive to innovate and to optimize projects for embodied carbon reductions. The architectural firm Miller Hull, for example, has committed to offset embodied carbon emissions of the projects they design, and more AEC firms may follow their lead. Carbon caps for specific building materials and products are another avenue for carbon reduction, and a promising mechanism to incorporate carbon reduction into Holistic Bidding. Many designers are already estimating the GWP of systems and materials they are

intelligent glass solutions | spring 2022

EXECUTIVE BOARDROOM COMMENTARY

specifying. Benchmarking to industry average GWP values or design estimates and prioritizing bids that meet or exceed the benchmarks can provide another incentive for supply chain transparency and decarbonization. Bids showing carbon reductions over the baseline would be prioritized, and those that do not would require revision before consideration.

What can contractors and manufacturers do? Elevate carbon as a factor in their supply chain evaluation and decisions, especially when they are highly dynamic. Further measure and document the environmental impact of their production via EPDs. Propose more low-carbon alternatives to standard designs, processes, or products.

Although not yet widespread across all North American jurisdictions, regulation will also increase transparency and drive innovation in embodied carbon reduction. One example of this is the Buy Clean California Act (BCCA), which governs procurement on state projects. BCCA caps embodied carbon for specific building materials, including flat glass, and requires contractors to submit facility-specific Environmental Product Declarations (EPDs) documenting the product’s environmental impact. The current GWP limit on flat glass is 1.43 metric tons of CO2eq per ton of flat glass. BCCA contains a mechanism to reevaluate and potentially lower the GWP cap every three years to drive greater reductions in the future, compelling manufacturers to continually reduce their emissions below the threshold.

What can owners do? Track their emissions and educate themselves about the impact of their choices. If starting small is the only option, start small. Forward-thinking owners with the ability to work at a larger scale can set ambitious goals for reduction of emissions, both operational and embodied and hold designers and builders accountable for reaching them. What can policymakers do? Policy often lags behind innovation in design and technology, but policy can drive widespread adoption beyond the small circle of forward-thinking early adopters. A wide array of policies can incentivize building industry decarbonization, from grid decarbonization to emissions caps to

Buy Clean policies are being adopted by an increasing number of public entities such as the City of Los Angeles, are in development in other U.S. states and cities, and can even be translated to private sector building owners. Tellingly, the White House recently announced that the federal government is developing a Buy Clean program. Taking the Next Steps Momentum to decarbonize the building industry is building rapidly, which leaves AEC professionals and built environment stakeholders asking: where do we go from here? Everyone involved in the design and construction process has a shared responsibility in reducing environmental impacts. Knowing that none of us can solve the problem of decarbonization alone, change requires development of creative ideas in a culture of mutual contribution and benefit. What can designers do? Learn more about manufacturing and the weight of their decisions. Measure and optioneer creative ideas with input from manufacturers. Consider crossing the entrepreneur wall and joining the industry. 16

Transparency is a critical step to decarbonization, and all stakeholders in a project must be aware of the impact of their decisions may have on the environment. Photo: Jason O'Rear | Golden State Warriors

intelligent glass solutions | spring 2022

zoning regulations. The City Policy Framework for Dramatically Reducing Embodied Carbon provides policy templates, allowing cities to choose which frameworks are likely to be most effective for them. Leadership is also needed at the national level, including emissions caps similar to the Buy Clean California Act and mandatory disclosure of environmental impacts via EPDs. The Future of Decarbonization and Environmental Stewardship Building on the advances in operational efficiency of the past decades and the accelerating developments in embodied carbon calculation and reduction of the present, the future of decarbonization is promising, but not without its challenges. While policies remain the most effective way to enforce best practices, they typically lag behind market innovation. The widespread and immediate switch to triple glazing as a standard practice after the passing of Local Law 97 in New York demonstrates that in many cases, the primary problem is not one of technology:

EXECUTIVE BOARDROOM COMMENTARY

it is the lack of incentives to adopt better technology. To face the carbon crisis head-on, we need to find the junction of innovations in technology, policy, procurement, financing, and design. Clients, customers, and designers can no longer afford to ignore the impact of their consumption. Transparency is critical to decarbonization, and all stakeholders need to know the impact of their decisions. Manufacturers must propose new products and develop low-carbon technologies to stay ahead of regulations. Whole life considerations will also be key, to ensure that lower carbon products have the same (or better) durability as their carbon-heavy equivalencies. Beyond carbon, design for circularity and material health for both building users and communities where building products are manufactured should remain amongst the top considerations. Decarbonization is the foremost challenge facing the building industry, and one for which

we do not have perfect or easy solutions. The costs of carbon through the life cycle of buildings, from manufacturing, transportation, use, and less tangible social costs, are of paramount concern and must be addressed. Innovations and re-evaluating the status quo have led to improvements, but there is still a long way to go. By reaching a shared understanding of definitions and calculations, best practices in all steps of manufacturing and construction, and looking beyond that

narrow focus to see the social costs of the carbon emissions for which we are responsible, the industry can change. Regulation and policy may be required to compel some of this change, and we are positioned to defend its importance and make it possible. By working together, all stakeholders can take meaningful steps toward reaching our goals of carbon reduction, shrinking the impact our industry has on our planet while still maintaining the integrity of our vision and design.

Laura Karnath Senior Associate Senior Enclosure Technical Designer Laura is a registered architect with a background in computational design and experience working with globally distributed project teams delivering highly complex projects. As a senior enclosure technical designer at Walter P Moore’s Los Angeles office, she brings her expertise and passion to the problem of decarbonizing the built environment through high performance, low carbon facades. She is a member of Walter P Moore’s Sustainable Design Community of Practice and a contributing author to the report Embodied Carbon: A Clearer View of Carbon Emissions. Laura is a co-founder of the Los Angeles hub of the Carbon Leadership Forum where she works to connect professionals across the AEC industry to share best practices and innovative approaches aimed at radically reducing embodied carbon in building materials and construction. Prior to joining Walter P Moore, she worked as a consultant at Gehry Technologies, where she gained experience in the organizational models and technical challenges involved in the delivery of large international projects. She holds an M.Arch from SCI-Arc and a B.S. in Architecture from SUNY Buffalo.

Sophie Pennetier Associate Director Special Projects Sophie holds 15 years of experience in the design of complex structures and facades. She joined Enclos in 2018, where she has steered various projects’ specialty facades scope sales and design assist efforts, engaged in prototyping, kit of parts curtainwall systems, structural glass, and various R&D topics such as ultra-thin glass, facades acoustical analysis and sustainability. Prior to joining Enclos in Los Angeles, Sophie worked as a Structural Engineer with Arup in New York, SHoP Construction, and RFR in Paris. In 2010 through the industry-academia partnership IAPP ARC between RFR, Evolute and the Vienna University of Technology, she developed cold bent glass numerical analysis tools for freeform facades. Sophie authored several research papers on structural glass and has been involved in the development of US structural glass codes with ASTM, the Journal of Architectural Engineering as an Associate Editor, and the Facades Tectonics Institute where she has served as a Paper Reviewer, 2020 Congress Organizing Committee, Special Advisory Council and currently sits on its Board of Directors.

intelligent glass solutions | spring 2022

Exploring New Frontiers in Glass To boldly go where no man has gone before OVER

1 Million

PAGE VIEWS PER ANNUM

igsmag.com

3,800

100,000

AVERAGE ADVERT BANNER HITS PER MONTH

PAGE VIEWS PER MONTH

FROM

10,000

NEWSLETTER SUBSCRIBERS

15,000

ONLINE E-MAGAZINE HITS PER ISSUE

20,000

UNIQUE VISITORS PER MONTH

190

DIFFERENT COUNTRIES

ARCHITECTS

27%

ENGINEERS

23%

CONTRACTORS

14%

SUPPLIERS

13%

MANUFACTURERS

SPECIFIERS

14%

A truly global audience 70%

Over of our readership are ultimate decision makers within this profession:

Founding Partners, Owners, CEO’s, Managing Directors, and Partners. IGS reaches over 190 different countries spread across all continents, however the top 5 countries are:

United Kingdom, Germany, France, USA and the Netherlands.

Photo by Adam Miller on Unsplash

EXECUTIVE BOARDROOM COMMENTARY

Achieving a virtuous circle: Driving circularity in the glass industry Graham Coult, Eckersley O’Callaghan, Technical Director and Rebecca Hartwell, Cambridge University, Research Partner

Float line The cullet producer carries the cullet to the float line, where it will be purchased by the glass manufacturer after being scanned for quality control. © Saint Gobain Glass UK

intelligent glass solutions | spring 2022

EXECUTIVE BOARDROOM COMMENTARY

lass has the potential to be endlessly recycled without degrading in quality. Yet it’s estimated that less than 10% of flat glass is recovered from buildings in the UK. What can be done to get more recycled glass back into the supply chain so that this dismal statistic can be improved? That’s the task we at Eckersley O’Callaghan set ourselves two years ago after joining up to Engineers Declare. By signing up to the agreement, we had a duty to think about circularity. We’re in an ideal position to understand the problem and influence change through our close links not only with our network of construction industry colleagues and clients, but with the people who make glass, and who make things out of glass. After two years of talking to the whole supply chain from the raw material suppliers through to glass consumers, from building developers to demolition companies, we are ready to share our insights, ahead of a soon-to-be-launched regional pilot project to test a more circular approach for flat glass. We believe there is the potential to reduce the annual emissions of the UK flat glass valuechain by up to 16%1 by recycling end-of-life flat glass back into the chain of production. Before considering how to deliver greater circularity, our research needed to understand not only the processes of flat glass production, but those of the wider glass industry as well. We then analysed the efficiency of existing and potential recovery routes for flat glass with their implications for materials, energy use and emissions. Glass is classified as one of the eight energyintensive sectors in the UK, accounting for 0.5% of total UK energy consumption2 and 0.5 - 1.0% of total UK greenhouse gas emissions in 20193. A total of 3.5 million tonnes4 of glass is produced annually in the UK. Container glass accounts for approximately 60% of production, flat glass for 22%, and glass wool for 10%. During the production process, glass waste of sufficient quality to be returned to fabrication, known as cullet, is added to the melt of the raw materials used to produce glass, typically at a level of 10-25%. This has several benefits. Firstly, it improves efficiency by reducing the demand for primary raw materials - the 20

use of 1 tonne of cullet saves 1.2 tonnes of raw materials. Secondly, it reduces energy demands in the melting phase, leading to a cut in energy consumption of 2.5 – 3.0% for every 10% increase in cullet5. Thirdly, this has a corresponding reduction in both combustion and process emissions. An oft-quoted statistic is that for every tonne of glass included in the glass melt, 580kg of CO2 is saved (although this figure varies according to many variables). Cullet can be one of three types – internal glass produced during the manufacturing

intelligent glass solutions | spring 2022

process; off-cuts of certifiable quality returned by fabricators; and post-consumer glass. Currently, the market for post-consumer cullet isn’t sufficiently developed, with the result that 90-95% of post-consumer glass ends up being downgraded either for end of life uses such as aggregates or additives for paint, or worse still, as landfill. We need to change perceptions so that instead of consigning this cullet to be waste, it is instead considered as material stock for recovery in a closed-loop process. The potential benefits are significant - our research indicates that in the extremis case the

EXECUTIVE BOARDROOM COMMENTARY

The Glass Production Cycle is a product of the research we have conducted with the links we have identified for each strand of the glass supply chain, from production through to disposal and recycling, while identifying the potential for the application of circular economy principles. © Eckersley O’Callaghan

replacement of 100% primary raw materials with 100% post-consumer cullet gives a total energy saving of 27%, with a reduction in total emissions of 41%1 from raw material sourcing through to the production of uncoated flat glass product. While the use of 100% cullet has been shown to be possible, in the short term the emphasis should be on redirecting flat glass waste to the higher value secondary uses including: container, flat or glass wool, and subsequently building up the supply chain for the longer-term goals.

The existing ~10% rate of recycling building glass back into production means that an estimated 180,000 tonnes of embodied carbon are being downgraded each year as a result of the glass that isn’t recycled. This is seen as a conservative estimate, and the figure could be as high as 700,000 - 900,000 tonnes. It's a very different story elsewhere in the glass industry. There is a well-established take-back infrastructure for container glass recycling, driven by packaging industry legislation and the ease of kerbside recycling. This reached a

record recycling rate of 76.5%6 in 2019, which sits within the average rate for Europe. In this sector, manufacturers are also looking to decarbonise the production process with increased use of cullet, with new container glass production containing 50-52% post-consumer cullet from UK sources 7, 8. This rate of recycling is assisted by container glass manufacturers being able to tolerate higher levels of contaminants in the raw materials. The glass wool sector uses up to 80% of cullet. Currently the glass industry’s plan to achieve

intelligent glass solutions | spring 2022

EXECUTIVE BOARDROOM COMMENTARY

being recovered. Glass recovery may lead to a slower demolition process. There is a lack of understanding of the options that could offset any additional associated costs on-site. Small pilot projects in France suggest that cullet can cost half the price that flat glass manufacturers would pay for raw materials, so there is commercial potential, especially if the glass goes straight to the manufacturers rather than through multiple intermediaries.

Our transformation of the 1968 listed building at UNESCO's headquarters forms a pilot recycling project in Paris audited and approved by glass manufacturers for certain recovery protocols. © Eckersley O’Callaghan

We’ve been talking to leading flat glass manufacturers in the UK, to try to understand their approach and what’s preventing them from using more cullet, given the known savings in raw materials and energy costs. Currently flat glass cullet that is collected is predominantly sent to container lines instead. Aside from supply, the key concern for flat glass manufacturers is fear of contamination – how to make sure that any post-consumer glass they’d be receiving back into the supply chain would be free from contaminants such as glass-ceramics, organic materials and metals. This reticence is understandable. In an industry where the margins are so minimal, having to stop production to deal with contamination issues in the float tank has major commercial implications. The stakes are much higher regarding contamination in the flat glass industry compared with container glass – one critical defect in a jumbo sheet could result in 350kg of waste compared to 400g for a glass bottle.

UNESCO's facade glazing panels are knocked out from frames to provide high quality cullet with low contamination risk. © Eckersley O’Callaghan

carbon neutrality by 2050, led by British Glass and the Department for Business, Energy & Industrial Strategy, is primarily focused on furnace technology and fuel-switching. Our complementary initiative focuses on reducing energy consumption and emissions through greater use of post-consumer cullet. This will require the action and participation not only of the glass industry but the broader building supply chain. So what are the barriers to increasing the use of post-consumer cullet for producing new flat glass? A key impediment is the lack of 22

supply due to so little glass being recovered when buildings are redeveloped, in contrast to far higher value materials such as aluminium, copper and steel. Instead, glass is knocked out and crushed, much of it ending up in landfill where it incurs a rate of just £3.10 per tonne as a lower rated material compared with £96.70 per tonne for standard rated materials (at 2021 prices). We spoke to demolition companies and found them open to change but ultimately governed by the fast pace of their contracts, which results in only high value and easily retrievable materials

intelligent glass solutions | spring 2022

The challenge is to find a way of minimising the risk of contamination. A unified set of specified grades of cullet that is agreed by flat glass manufacturers and reprocessors will be a major goal. There’s a great deal of work to be done here to establish these assurances of high purity, and in doing so provide greater certainty that there will be a market for the cullet after the cost outlay of glass recovery. Nonetheless, we feel there is the potential to create unified specification grades for the maximum level of contaminants that would enable the market to operate more effectively. Glass recovery from site is not a significant technological challenge, more a matter of logistics and quality control, and something that can certainly be overcome. Indeed, those who understand this and can provide efficient construction methods will stand to gain. The Waste and Resource Action Programme

EXECUTIVE BOARDROOM COMMENTARY

(WRAP) introduced some quality protocols for glass recovery from site back in 2008 but it was too early for the industry. Further work was carried out in the Buildings as a Material Bank (BAMB) project in 2020. This needs to be revisited to draw up on-site recovery standards for recycling building glass into cullet. Alternative mechanisms for collection that sort flat glass cullet more effectively should be investigated. We think it would be beneficial to consider grading post-consumer flat glass cullet to then distribute to relevant glass markets based on quality. Improved scanning technology to identify contaminants could also help.

The original windows at Panther House in London comprise of small glass panels in iron frames which will have a complicated and unlikely recovery process after demolition has taken place. © Eckersley O’Callaghan

We can learn from a pilot recycling project at the UNESCO building in France. For this, flat glass manufacturers have audited and approved certain recovery protocols so that the demolition contractors have to deliver the framed glazing panels into stillages. The panels are then transported to a cullet factory where the glass can be simply knocked out from the uPVC or aluminium frames to provide high quality cullet with a low risk of contamination. The cullet producer then organises collection of the cullet by the glass manufacturer. The total amount of cullet produced for recycling on this project is estimated at 113 tonnes. Based on the

These internal glass partitions in the offices of Lafayette Anticipations in Paris, are an ideal building component for recycling as they are easy to process. © Eckersley O’Callaghan

intelligent glass solutions | spring 2022

EXECUTIVE BOARDROOM COMMENTARY

St Helens recovery loop is a Pilot project to enhance the waste strategy in the area by reducing the amount of glass going into landfill and increasing recovery of window glass at quality sufficient to produce new glass. © Eckersley O’Callaghan

assumption that 1 tonne of glass saves 580kg of CO2, the cullet recycling should avoid 66 tonnes of CO2 emissions.. So, what else can be done to encourage change? So far there just hasn’t been the collective thinking that’s needed to drive a more circular approach from developers right through to the glass industry. Until we get this, people will fight against change and continue to benefit from the status quo of putting waste glass in the ground. However, during the latter period of our research, we’ve noticed a sea change in approach. Attitudes are starting to change – we’ve noticed that the idea of using more post-consumer cullet is starting to be viewed more favourably. We can see a way to explore simple opportunities in the domestic 24

market but the commercial side will require significant effort to embrace the change. Everyone has to play their part. We need owners and developers to make the commitment to recover the glass from their buildings and prioritise it for high-value recovery options. The demolition contractors need to be able to better understand the costs of recovery. So far this isn’t happening – our research found less than a handful of projects in the UK where developers had sought a market for the recovered glass. We need architects to specify that all the glass in the building they’re retrofitting should be recovered where practical. The recovery of internal glass partitions, for example, is much easier to process than a small panel in a filigree iron frame. How

intelligent glass solutions | spring 2022

do we get glass recycling on the agenda of contractors and their coordinated engagement? Could they work together to establish recycling plants at locations of easy access? There needs to be a carrot and stick approach. We’d like to explore the use of planning guidance to encourage glass recovery by mandating glass recovery from commercial demolition where practical. We’d like to see the requirement for a full assessment of the potential for glass recycling as part of the demolition application – buildings with extensive glazing are likely to be more suitable candidates than those with small pockets of glass. A predemolition audit should cover this in greater detail and should be verifiable. Perhaps there could be the potential for offsetting glass that

EXECUTIVE BOARDROOM COMMENTARY

isn’t recycled in some other way that would still benefit the recycling process. Perhaps there is scope to encourage glass recycling more strongly through the BREEAM assessment system, where we are working with the Technical Working Group to develop the next guidance. We believe the domestic market – which is considerably larger than the commercial market – presents more straightforward opportunities for circularity for relatively modest investment. We are developing a pilot project for St Helens – fittingly where Pilkington was first established – in collaboration with Arup, British Glass, Diageo, Glass and Glazing Federation, Glass Futures, Pilkington - NSG Group, Saint Gobain, The Glass Company and St Helens Borough Council. This was initiated at COP26 and we hope to launch it this spring. The aim is to enhance the waste strategy in the pilot area by reducing the amount of glass going to landfill and increasing the recovery of window glass at a quality that can be used to produce new glass. In doing so, this will reduce both energy use and carbon footprint.

Glass waste of sufficient quality to be returned to fabrication is known as cullet where it is added to the melt of raw materials used to produce glass. © Saint Gobain Glass UK

We are optimistic that with the right will and organisation this can succeed. Our approach is to work with installers to dispose of insulated glazing units or framed glazing at a network of local recovery plants in a way that will allow recycling through appropriate segregation and

storage. This cullet can then be sold on the open market, whether for use in container glass or in flat glass manufacture - either destination means a reduction in raw materials and energy used. The cullet will either go straight back to the glass manufacture or via a bulking station

Leading glass manufacturer Saint Gobain’s Eggborough factory. © Saint Gobain Glass UK

intelligent glass solutions | spring 2022

EXECUTIVE BOARDROOM COMMENTARY

and reprocessor. While such an approach has already been shown to be effective at a small scale, this level of intervention to stimulate the market is unprecedented. We see a role for glass industry organisations such as British Glass and the Glass and Glazing Federation in promoting the benefits of the initiative throughout the industry. In other established programmes such as Vlakglas Recycling in the Netherlands, the insulated glazing unit (IGU) manufacturer supports the glass processing required for recycling through a levy on the price of glass per square metre of IGU to help fund the recovery for the cullet. During the pilot study, cullet volumes and quality will be monitored – including contaminant levels before and after reprocessing. Transportation distances will be tracked to monitor associated costs and carbon expenditure. The results should equip us with sufficient knowledge on costs, logistics and carbon reduction to demonstrate the efficacy of the establishment of flat glass take-back infrastructure in the UK. It will also enable us to understand what it takes from a local perspective to develop recycling networks of this nature. The aim is to learn enough from this exemplar project to produce a scalable business case for wider application to help drive a market for flat glass cullet. There is potential to roll it out with local fabricators across Merseyside and beyond with a view to securing a national approach.

1 Rebecca Hartwell, Graham Coult, Mauro Overend; Mapping the flat glass value-chain: A material flow analysis and energy balance of UK production; 07 March 2022; PREPRINT (Version 1) available at Research Square; https://doi.org/10.21203/ rs.3.rs-1401635/v1 2 WSP Parson Brinkerhoff; and DNV GL, “Industrial Decarbonisation & Energy Efficiency Roadmaps to 2050: Cross Sector Summary,” 2015. 3 R. Ireson et al., “Alternative Fuel Switching Technologies for the Glass Sector,” 2019. [Online]. 4 Glass Sector Net Zero Strategy 2050, British Glass

Graham Coult, Eckersley O'Callaghan, Technical Director With 20 years’ experience as a structural and facade engineer, Graham has a particular passion in the development of structural glass design using sophisticated analysis and modelling tools. Graham's technical expertise in pioneering glass engineering has been instrumental in delivering the practice’s many challenging and awardwinning glass projects, notably for Apple. As Technical Director at Eckersley O'Callaghan, Graham is responsible for the strategic operations across the company. This includes defining design processes and project delivery for project excellence. He also leads our R&D programme driven by a pursuit to explore the innovative use of material in design.

We would also look to identify upcoming regional refurbishment and demolition projects from commercial buildings to act as exemplars, and to understand the changes and opportunities for driving recycling in the commercial sector. After two years of research, we have gained valuable insights into the challenges of recycling glass back into the manufacturing process. There’s the potential to learn a great deal more as we drive this project forward, but we can’t do it alone. We need collective action. This is a call to arms to both the glass world and the wider construction industry. We need to raise awareness of what can be done to drive greater circularity by joining together across the sector in a spirit of cross-disciplinary innovation. Only then can we bring about the muchneeded changes required. 26

intelligent glass solutions | spring 2022

5 R. Beerkens, G. Kers, and E. Van Santen, “Recycling of post-consumer glass: Energy savings, CO2 emission reduction, effects on glass quality and glass melting,” in Ceramic Engineering and Science Proceedings, 2011, vol. 32, no. 1, doi: 10.1002/9781118095348.ch16. 6 FEVE, “Latest Glass Packaging Recycling Rate Steady at 76%,” 2018. https://feve.org/glass_recycling_ stats_2018/ (accessed Dec. 03, 2021). 7 FEVE, “Close the glass loop: The action plan for the UK,” no. June, 2020. 8 P. Lee, N. Bell, T. Garcia, O. Lee, J. Harding, and K. Baker, “Recycling DRS in Scotland,” 2019.

Rebecca Hartwell, Cambridge University, Research Partner Rebecca is a PhD candidate in the Glass and Façade Technology research group at Cambridge University under the supervision of Professor Mauro Overend (TU Delft). She previously graduated in Material Science and Engineering from the University of Manchester which included a 1-year industry placement at Siemens Magnet Technology. Subsequently, Rebecca worked as a research assistant at the International Centre for Advanced Materials, to develop research in understanding the role of microstructure in the failure of insect cuticle using X-Ray Computed Tomography. Her current PhD research is developing the knowledge, tools, and technologies to promote the effective reuse and high-value recycling of building envelopes.

EXECUTIVE BOARDROOM COMMENTARY

Design freedom without compromise Realise your project aspirations with leading product solutions in curtain wall. With bespoke and standardised product solutions from Reynaers Aluminium, you can rely on: Expertly engineered systems that perform to your thermal and acoustic requirements Uncompromising quality and craftsmanship Support that matches your project programme, timescale, and budget World leading curtain wall solutions Achieves many test standards including CWCT (dependant on variants) Structural glazing, unitised glazing, roof glazing and fire rated solutions available

Together for better Reynaers Aluminium

reynaers.co.uk 0121 421 1999 reynaersltd@reynaers.com intelligent glass solutions | spring 2022

EXECUTIVE BOARDROOM COMMENTARY

Carbon-led Façade Design Gianluca Rapone, Associate and Sustainability Lead at FMDC, envisions what it will take to design façades with carbon saving as the main driver

Cultural shifts By now we should all be aware of the crucial role the construction industry plays in reducing global carbon emissions; it is also obvious that it is naïve to think that everything can be solved merely with technical innovation and engineering optimisation. The whole industry will need to change radically if we want to come even close to achieving the carbon reductions required to keep global temperatures within the critical 1.5°C rise advised by the IPCC. We should expect shifts in clients’ expectations and in public perception, new economic and business models, a deep re-think of the way we design, procure, build, occupy, and decommission buildings. Essentially a change of culture in the world of architecture and construction which will involve pretty much every aspect. 28

intelligent glass solutions | spring 2022

EXECUTIVE BOARDROOM COMMENTARY

2 Trafalgar Way is a mixed-use development in East London designed by APT Architects. It was designed to minimise energy demand and consumption as it aims to become the largest PassivHaus certified building in Europe. However, there were no embodied carbon targets for the project. (CGIs courtesy of APT Architects, under permission by Urbanest)

intelligent glass solutions | spring 2022

EXECUTIVE BOARDROOM COMMENTARY

Although I consider such broader matters crucial, the remit of this article is limited to exploring the changes that I believe are required in the façade construction process, from design to procurement, from manufacturing to maintenance, all the way to end of life. Several publications by institutions like the UKGBC and LETI have informed us on the likely technical characteristics of ‘net zero’ buildings. Furthermore, comprehensive research has highlighted the need for circularity in the construction industry. The façade is put under enormous pressure by all these targets, from both operational energy and embodied carbon perspectives. A ‘business as usual’ approach, even if improved, will not deliver the necessary savings. We need to question every choice we used to make with the old model, and adopt a new attitude where carbon is at the centre of every decision.

One Park Drive © Paul Scott

Design for real performance The role of the façade in reducing operational carbon is inevitably interconnected with the wider approach to a building’s energy efficiency. Regulating energy demand via passive or active measures, while ensuring that the occupants’ thermal and visual comfort can be achieved is a subtle balance of conflicting requirements and inter-dependent factors.

Upfront embodied carbon of typical façade designs compared to present and future targets, for commercial and residential buildings. Significant reductions will be required.

intelligent glass solutions | spring 2022

EXECUTIVE BOARDROOM COMMENTARY

Over the years, finding the appropriate solution to this problem has somehow strayed from its natural path due to what can be called ‘compliance culture’. The objective has not been to achieve the best possible performance as a whole, but instead to make sure single components comply with the relevant standards and with ‘box ticking’ environmental targets, whilst safeguarding architectural appearance. This however is finally changing in favour of a ‘design for performance’ approach, promoted by strict energy intensity targets for ‘net zero’ buildings, and by the adoption of performance-based rating schemes such as NABERS. In this context, we have the opportunity to go back to the drawing board and re-think every aspect of building design to enable the required energy savings. Basic architectural factors, such as early-stage massing, orientation and glazing percentage can have a significant influence on heating and cooling demand. The building ‘Form Factor’ governs the heat loss area, which in turn determines how hard the façade will need to work to achieve the heating demand target. Simply put: the most compact the building, the higher the heat retention, the less pressure on thermal performance of the envelope. Architects have the opportunity to set a project on the right path from the start, especially because an efficient form factor is also key for the façade embodied carbon budget, as we will observe in the next section.

One Park Drive in Canary Wharf is an elegantly designed residential tower by Herzog & DeMeuron, boasting white fluted terracotta tiles on unitised curtail wall. The lively articulation of the façades is its most distinguished feature; however, it also means that the form factor is not as good as it could be for a circular floorplate. When designing low-carbon buildings, building shape will be an important aspect to consider. © Paul Scott

When it comes to cooling loads and overheating, the matter becomes more intricate. The role of façades as ‘filters’ is a concept that has been around for centuries. Its modern interpretation is rooted in the technological developments of the midlate XX century, when increasingly complex solutions were introduced, mainly to control solar gains and daylight. Dynamic shading solutions can vary from simple (reflective blinds) to extremely advanced (DSF or CCF); although they are undoubtedly more efficient than static ones, very complex systems can add capital cost, maintenance needs, and embodied carbon. The aim on every project should always be to use to the simplest possible category that allows requirements to be met. This hasn’t always been the case in contemporary commercial buildings.

intelligent glass solutions | spring 2022

EXECUTIVE BOARDROOM COMMENTARY

Farringdon East is a commercial building designed by PLP, with floor to ceiling glass and brightly coloured terracotta tiles. Future offices will likely need to reconsider the amount and configuration of glazing to achieve stricter U-value targets. © Paul Scott

Farringdon East © Paul Scott

A big issue with dynamic solutions is that their predicted performance is either modelled incorrectly, or not modelled at all. Mostly because of outdated tools used to prove compliance, but also due to lack of specific modelling knowledge, in the past we have missed the opportunity to properly specify these types of solutions and integrate them within the daily operation of buildings (either by BMS or manual occupants’ action). An update of regulations is necessary to reflect ‘design for performance’ strategies and accept the use of dynamic simulation modelling which is more accurate in predicting real performance. Reducing the performance gap goes hand in hand with designing for performance. In the context of façades, it translates to setting more

intelligent glass solutions | spring 2022

EXECUTIVE BOARDROOM COMMENTARY

Variation of U-value with glazing percentage for different façade solutions, compared to typical and ‘net zero’ target ranges. Rigorous U-values can only be achieved with lower glazing percentages.

realistic targets, a stricter scrutiny of calculations and installation during construction, and monitoring actual performance to implement feedback loops into the design phase. Embodied carbon first Embodied carbon is a relative new factor, but one that has quickly taken centre stage because of its substantial weight in the whole life carbon balance. Operational energy has been the main focus for decades and its reductions have now reached a point of diminishing returns. On the contrary the role of embodied carbon has been overlooked until recent years and has now become the priority.

10 Fenchurch Avenue, a commercial building designed by Eric Parry, includes a CCF (Closed Cavity Façade) with dichroic glass on the top five levels. The effectiveness of complex façade systems will need to be questioned in a whole life carbon context, taking into account grid decarbonisation. © Paul Scott

The trade-off between operational and embodied carbon is of key importance, as illustrated by this question: in a whole life scenario, is the reduction in future operational carbon brought about by triple glazing worth the additional embodied carbon? The answer depends on factors that are both project specific and general (e.g., grid decarbonisation, performance gap), and it’s hard to predict. Notwithstanding the actual answer, this example introduces the concept of ‘Carbon payback periods’; these will become a necessary tool to evaluate the whole life carbon impacts of important facade design decisions, such as whether to opt for a double skin or intelligent glass solutions | spring 2022

EXECUTIVE BOARDROOM COMMENTARY

Potential carbon impacts of the use of triple glazing in lieu of double glazing in the context of its typical design life (25 years), for different scenarios of grid decarbonisation.

Influence of building geometry on embodied carbon budgets for the façade. The most compact the building, the higher the budget (i.e., the easier to achieve).

a closed cavity façade. For too long we have been striving exclusively for operational savings, now the focus should be on embodied carbon. Recently the Carbon Emissions (Buildings) Bill, kickstarted by the Part Z initiative, has made its way to Parliament; when approved its impact will be substantial. 34

The contribution of the envelope to the overall embodied carbon of a building can vary depending on the type and characteristics of the project, but it’s one of the major factors with a proportion that can range from 10% to 20% approximately. The percentage is most likely going to increase in the near future

intelligent glass solutions | spring 2022

because other elements of construction, such as the structure, are a step ahead in the pursuit of reducing their carbon content. Before delving into specific materials, it is extremely important to point out that the basic geometrical characteristics of a building

EXECUTIVE BOARDROOM COMMENTARY

can have a big influence on how the façade contributes to the overall embodied carbon. The ‘Form Factor’, which is essentially the ratio between envelope area and GIA, governs this relationship: the more inefficient the form factor, the higher the impact of façades. We can also express this concept the opposite way around: given an overall target, an inefficient form factor translates to a stricter carbon budget for the façades. This is why architectural considerations on building shape, floorplate size, and inter-storey height become very important. The large number of materials, processes, and construction systems used in façades makes an embodied carbon calculation convoluted. Generally, sustainability consultants do not have a detailed understanding of how façades are manufactured, built, and maintained, which can lead to significant errors in the assessment. Lack of consistency in the data provided by EPDs also adds to the uncertainty. A common approach coupled with defined guidelines is clearly necessary. The CWCT (Centre for Window and Cladding Technology) is addressing this lack of direction and has formed a committee that is currently working to develop a common methodology to calculate embodied carbon of façades. Material matters The unrelenting timescale dictated by the climate emergency does not give us the luxury to wait for new low-carbon materials. Besides, two of the most fundamental materials in cladding, aluminium and glass, are not easy to substitute; unfortunately, these also happen to be the main culprits of carbon content in cladding. Timber is seen as the potential saviour, but its implementation in façades on a large scale might take longer than we hope, especially in the UK. Until timber or other low-carbon solutions catch on, the industry needs to focus on reducing the environmental impacts of the materials already in use by interrogating every aspect of their life cycle. The main actions can be grouped into four categories: de-carbonise production, optimise design, extend service life, improve opportunities for reuse / recycle. If we take glass as an example, manufacturers are already actively working on reducing the carbon footprint of float glass. In the UK, Glass Future’s ‘Industrial Fuel Switching’ initiative is

One Blackfriars, designed by Simpson Haugh, features a double skin façade with a fully glazed coated outer skin including ventilation louvres, and large sliding doors on the inner skin. The high embodied carbon due to the large quantity of processed glass would most likely exceed the expected targets for a residential development. © Paul Scott

intelligent glass solutions | spring 2022

EXECUTIVE BOARDROOM COMMENTARY

evaluating alternative fuels for glass furnaces, which account for the largest part of emissions in glass production. Moreover, plans are being put in place to increase the use of cullet, especially post-consumer one, which reduces CO2 emissions both directly (cullet was already decarbonated during the initial raw materials fusion) and indirectly (reducing energy by lowering the melting temperature).

One Blackfriars © Paul Scott

Designers should optimise build-ups structurally and design out the need for energy heavy processing such as heat treatment and lamination as much as possible. Avoiding floor to ceiling glass by raising it above 800 mm would negate the need for safety glass on windows: less laminated glass would not only reduce carbon content but also improve recyclability. Heat treatments could be limited by undertaking detailed analysis and by introducing measures to reduce the risk of thermal stress. If heat treated glass is necessary, accepting lower visual quality would allow to cut both waste and energy. More relaxed rules on pillowing would mean thinner glass in some instances. Renouncing extra-large glass sizes would mean avoiding the additional energy that comes with producing and installing them. All

Comparison of embodied carbon (A1-A3) for different glazing solutions and build-ups. (Data for chart was taken from EPDs by Saint-Gobain Glass)

intelligent glass solutions | spring 2022

EXECUTIVE BOARDROOM COMMENTARY

Unitised panels pre-installed on precast concrete slab sections off-site. The HRS system used by Mace to build East Village N06 allowed significant reductions of waste materials and number of site deliveries. Image credits: Mace Tech.

the above measures will have impacts on visual appearance and risk, challenging architects’ expectations and clients’ judgements. IGUs need replacing at least once during the typical life span of the building, essentially doubling up in embodied carbon. Research into methods to extend their service life is ongoing, and includes studies to improve longevity of edge seals, alternative strategies such as pressure equalisation, or the development of technologies to refill the gas. There are other examples where innovation can come to the rescue, hence the importance of funding and industry engagement to accelerate the transition from research to practical solutions. Recycling glass has already been mentioned as a way to reduce emission from float glass production, but its importance is much greater when considering ‘zero waste’ targets. As part of the ‘Glass Forever’ initiative, SaintGobain Glass has committed to increasing the proportion of cullet in its glass to 50% by 2025. Key to this is the cullet return scheme put in place to collect post-consumer glass, process it, and re-introduce it into manufacture of new glass.

Similar considerations can be made for other materials used heavily in cladding, from aluminium to concrete, from terracotta to stone. Furthermore, the use of alternative materials with lower environmental impacts should obviously be considered where possible: for example, the energy required to produce zinc or copper rainscreen panels can be 8 to 20 times lower than aluminium. Closing the loop Regrettably, addressing upfront embodied carbon will not deliver the ‘whole life’ net zero ambition. We need to look beyond the service life of building elements and think about how we can reuse or re-cycle them in the future. This is a big challenge for an industry that until few years ago didn’t think much about what would happen to the building in operation, let alone at the end of its life. Cladding systems lend themselves very well to pre-fabrication, which allows a better-quality control, faster installation, reduced risks on site, and the potential for easy disassembly. Modern Methods of Construction (MMC) involving façades are yet to catch on, but a trailblazing example was recently built in London. On the 'East Village' project in Stratford Mace employed

their HRS system (High Rise Solutions), where the unitised cladding panels were fixed to long strips of precast concrete slabs; the latter were then installed at the perimeter of the floorplate. On 2 Trafalgar Way, a mixed used development by Urbanest targeting PassivHaus Classic, the use of such off-site construction method is currently being considered. However, in the context of whole life carbon the most important question we will need to answer is not how we are going to build the façade, but what we are going to do with it at the end of its life. We can easily design for disassembly, but what happens then? The solution to this issue implies a change of attitude that involves a deep re-think of the traditional economic and supply systems governing the cladding market, to convert them from linear to circular. The barriers to wide adoption of circularity principles remain many. Although some of the technical hurdles are starting to be addressed by the façade industry, for example by improving transparency of information and introducing digital tracking of components, changes in commercial attitudes are trailing behind. The appetite to utilise used or recycled materials is still minimal, as it is cheaper and lower risk to use new ones. Most

intelligent glass solutions | spring 2022

EXECUTIVE BOARDROOM COMMENTARY

performance, which will need to be combined with significant reductions in the carbon content of cladding materials. Key strategies of waste reduction, circular models and retrofit at scale will also need to be adopted. The ambitious targets imposed by the climate emergency should be seen for what they are: a necessity, but also a great opportunity to make things right. They can only be achieved with a collective effort where clear end goals are shared by all stakeholders. The type of cultural changes required are typically slow to occur, but there is no time to waste in an emergency, so we should all act with more urgency.

Breakdown of contributions to embodied carbon (A1-A3) for a typical double glazed unit. The most ‘carbon heavy’ processes are clearly recognisable. (Data for chart was taken from EPDs by Saint-Gobain Glass)

Gianluca Rapone Gianluca is an Associate at FMDC, one of the top façade and materials consultancies in the UK. He is a façade engineer with a strong background in building envelope physics; before moving to the UK, he completed a PhD in Italy where he studied the optimisation of façade design for energy savings and comfort. Since joining FMDC in 2017, he has been leading the Building Physics team and he has worked on projects across all stages, from concept design to construction. In recent years Gianluca’s keen interest in sustainability and low-carbon design has led him to coordinate FMDC’s efforts in investigating the role of façades in reducing both the operational and embodied carbon of buildings.

Designing the façade for a ‘whole life net zero’ building will depend on the application of circular economy principles. (Icons credits: LETI)

importantly it is not commercially attractive, as there is no established market for the reuse of products and materials. The conundrum is that we are asked to design products to be reused in a market that doesn’t yet exist. If we want to create circular models, the priority must be to think of ways to retain the intrinsic value of products and materials by keeping them in use. If we imagine the building as a material bank, the façade would probably be the most valuable asset because of its density and variety of materials in limited space. On the other hand, because of such diversity, creating closed loop systems would not be trivial. The ’Façade ReLog’ project was created by TU Delft to unlock the potential for the recovery of metals and components in the European façade industry. By bringing together different stakeholders it tries address practical topics such as business models, industrial processes, and recovery logistics. 38

Another more radical approach could be to turn the façade from product to service. This concept has been studied again by TU Delft through their ‘Façade Leasing’ scheme, which proposes a circular business model based on the use of façades as performance-delivering tools. The contractor / supplier becomes a service provider to the client, who leases the system and its performance rather than buying it. By retaining the ownership of their product, the supplier will commit to maintaining and upgrading it during building operation and will have the best interest to find ways to reuse and recycle components or materials at the end of their service life. Collective Urgency Designing building envelopes with carbon reductions as the main driver means adopting a whole life perspective where decisions are evaluated on the basis of trade-offs between operational and embodied carbon. Strict energy targets will dictate exceptional technical

intelligent glass solutions | spring 2022

EXECUTIVE BOARDROOM COMMENTARY

IGS Magazine Copywriting Service for Architecture, Glass and Facade Engineering Industries IGS has a passion for creative thinking and highquality content that makes a real impact. Our team of journalists and designers have over 30 years’ experience in publishing, writing and editing content specific to architecture, glass and facade engineering. Our aim is to deliver carefully considered, well executed content that builds your brand profile and connects you with your customers. So, if you’re looking for a creative content provider with a powerful injection of creativity to freshen the global face of your company, IGS Copyrighting Service could be just the tonic you need.

The greatest writing is clear and concise, consequently getting your message across effectively is sometimes easier said than done. Our experienced team of in-house journalists and editors raise your profile with thoughtful and intelligent copy that trumpets your story, hitting the right note every time: 1. Whitepapers 2. Case studies 3. Project write-ups 4. Editorials + Advertorials 5. Blogs 6. Press releases

“I am irritated by my own writing. I am like a violinist whose ear is true, but whose fingers refuse to reproduce precisely the sound he hears within.” – Gustave Flaubert If you can relate to this quote, contact Lewis to find out more: lewis@igsmag.com

intelligent glass solutions | spring 2022

EXECUTIVE BOARDROOM COMMENTARY

Design and engineer with less impact

1 Angel Square, Manchester - The building was the first BREEAM rated ‘Outstanding’ regional office building in the UK and is EPC ‘A’ Rated. Courtesy of NOMA.

intelligent glass solutions | spring 2022

EXECUTIVE BOARDROOM COMMENTARY

Carbon Neutral Silicones in Façades – a window of opportunity

Valérie Hayez, Jayrold Bautista

intelligent glass solutions | spring 2022

EXECUTIVE BOARDROOM COMMENTARY

lobal carbon emissions resulting from new and existing building stock are well documented. The 2016 Paris Agreement has sparked a plethora of lowcarbon options with many regions, cities and companies themselves creating their own carbon neutrality goals. Carbon targets will hence increasingly be required for planning permission with clients taking a more active role in developing a brief for commissioning their carbon measurements. Reductions in operational carbon - or from the energy used to power, heat and cool a building, have been tackled through energy efficiency measures and are where policymakers, developers, architects and engineers have made significant advances.

Prime Tower, Zurich, LEED Gold certification

The remaining carbon emissions are from building materials and construction. This “embodied carbon” becomes more important as energy efficiency increases and can account for half of the total carbon footprint over the lifetime of the building. Whereas operational carbon can be tracked, embodied carbon

emissions, which are primarily generated during production due to energy consumption using fossil fuels and waste, is much more difficult to quantify. Following the push of architectural associations (e.g. CTBUH or AIA American Institute of Architects), building owners and property developers, various tools (e.g. EOC₂, a new REVIT plug-in designed by Eckersley O’Callaghan) are emerging to measure embodied carbon and become the criteria for meeting leading green building sustainable certifications such as LEED or BREEAM through more challenging standard life cycle assessments (LCA) calculations. Shanghai Tower – Boasts certifications from the China Green Building Committee and the U.S. Green Building Council for the building's sustainable design

Dow Carbon Neutral Silicones for facades Dow has the will to take a leading role in supporting the development and

intelligent glass solutions | spring 2022

implementation of a more circular economy, taking into account a product’s lifecycle – from creation to use to disposal – in everything we do and generate. Dow has recently been focusing on developing sustainable raw material and sustainable production to reduce our footprint through various environmental, social and governance investments (ESG). Dow is the very first silicone manufacturer that will offset the carbon footprint for the silicone used on a project-by-project basis, through the supply of registered carbon offsets that will net zero the carbon footprint of the material used. The silicone sealant’s contribution to building’s scope 3 emission can now be neutralized through this unique offering.

EXECUTIVE BOARDROOM COMMENTARY

and production, but also through their use. Carbon-neutral silicones can help to enable a sustainable design, through material and energy efficiency. Operational and embodied carbon savings of new high performance façade design and in existing building stock can be realised through a combination of design and engineering of carbon-neutral silicones. The review of how silicones can contribute to a more sustainable design would not be complete without assessing their circularity at end of life and renovation possibilities.

Dow has a unique advantage of being fully backward integrated from manufacturing of Si Metal to Siloxane and the finished products. We offer carbon neutral silicone sealants for facade, based on our efforts to significantly reduce the high silicon metal footprint and offset the remainder by our own generated offset from within our supply chain. These continuous efforts result today in the launch of the world’s first commercially available global carbon-

neutrality program for silicone applications on building facades, which are verified to the internationally recognized PAS 2060 specifications for carbon-neutrality. A Dow carbon neutrality certificate can be requested on a project-by-project basis. It is important to note that these carbon-neutral silicones do not only contribute to a sustainable construction design through their sourcing

Carbon neutrality shall respect Environmental, Social and Governance aspects With around 11% of carbon being generated by building materials, an enormous and ongoing effort is required of manufacturers to continually reduce levels of embodied carbon. This requires a significant contribution and investment into enrivonmental, social and governance (ESG), also referred to as the “ESG carbon”.

1 Angel Square, Manchester. Courtesy of NOMA

intelligent glass solutions | spring 2022

EXECUTIVE BOARDROOM COMMENTARY

Figure 1: Dow’s back-integrated silicone manufacturing is a huge advantage

The biggest contribution to the embodied carbon of silicones resides in the raw material extraction and processing. Thanks to backintegration in the production process, Dow produces silicon metal with low carbon raw materials and renewable, non-fossil-fuel energy at two sizeable, protected rainforest locations. Raw materials are sourced and obtained locally. Dow utilizes quartz mines, waste from the wood industry and the Dow owned eucalyptus plantations. The production process is supplied largely with hydroelectric power. This allows to significantly reduce the silicon metal’s manufacturing footprint which dominates the overall emissions balance of a silicone production. To reach complete carbon neutrality, Dow is 44

using "insets", its own carbon offsets from the internal value chain, resulting from significant and sustainable investments in social capital. This is obtained not only from the above mentioned environmental investments, but also by making critical financial, educational and social investments in the local communities. Improving the area’s Human Development Index and discouraging further destruction of the Amazon rainforest are key initiatives. Dow is making a positive impact on the environment and local communities specifically with Project Ybá in the Amazon, which brings work to circa 4000 people living near the site, while producing the low-carbon materials needed for developing the first-ever carbon-neutral silicone sealants for high performance building façades.

intelligent glass solutions | spring 2022

Credible Carbon-Neutrality Services for Façades LCAs following ISO 14040:2006 and ISO 14044:2006 have been prepared for individual products and the resulting low CO2 emissions are offset as explained before. The LCA conformance review statements and Qualifying Explanatory Statements (QES) were externally (third party) audited following ISO standards mentioned above and PAS 2060 requirements respectively. The PAS 2060 standard is the most well-known and established standard for organizational carbon-neutrality. It includes an “ambitious commitment to climate action” and is intrinsically linked to the efforts of a company’s ESG values which are critical components of a carbon reduction journey. This standard, published by the British Standards Institution in 2010, provides a guidance on how to offset greenhouse gas (GHG) emissions and how to create a continuous carbon reduction plan. Offsetting using verified credits emphasizes and requires the support of climate finance projects with the aim of adding social and environmental value such as Dow’s project Ybá. Annual audits contribute to continuous progress in the journey of reducing and offsetting emissions. As part of the carbon neutral program, the QES, containing the carbon neutrality achievement declaration, can be requested per project. In parallel, the audited LCAs are used to produce Environmental Product Declarations (EPDs), which are a way of reporting the LCA data following so-called Product Category Rules (PCRs). PCRs provide category-specific guidance for estimating and reporting product life cycle environmental impacts, typically in the form of environmental product declarations and product carbon footprints.

EXECUTIVE BOARDROOM COMMENTARY

Lack of global harmonization between PCRs or sector guidance documents has led to the development of duplicate PCRs for same products. Therefore, it is important to bear in mind that the values of different EPD considerations are not comparable unless they were issued by the same program operator and follow the same PCR. Finally, Dow’s carbon-neutral program also includes guidance on the contribution of carbon-neutral silicones to securing green building certification credits/points. Building components can contribute to the overall rating if requirements of respective standards are fulfilled. The major schemes in place such as the internationally recognized BREEAM and LEED, and the Singapore Building and Construction Authority Green Mark (mainly recognized in Asia Pacific APAC and China) or the German Sustainable Building Council (DGNB) scheme (mainly used in central Europe) do include carbon-neutrality credits, mainly geared towards the major building components such as concrete, steel, and glass. The carbon neutrality of silicone sealants can also contribute to achieving credits from the innovation section of the green building ratings scheme. Dow’s carbon-neutrality program is available for projects involving structural glazing (SG,

bonded glazing), insulating glazing (IG) and weathersealing (WS), covering all geographical areas. This service is available for the following high performance silicones: • DOWSIL™ 791 and DOWSIL™ 795 Weatherproofing Sealants • DOWSIL™ 3362, 3362N, 3363EU, 3363CN, 3363US Insulating Glass Sealant • DOWSIL™ 993, 993N and 983 Structural Glazing Sealants As an illustration, the carbon savings for a representative façade using Dow’s carbonneutral silicones versus standard silicones can be calculated. The considered façade has insulating glass units of 1.3m width and 2.5m height. These units (of which 30% are considered to be triple glazed) have silicone secondary seals of 10x18mm² and are bonded on the frame with 15x6.4mm² structural seals. Finally silicone joints of 10x15mm² are used to weatherproof the whole building envelope. Assuming 10-15% silicone waste at application, the silicone consumption for the SG, IG and WS applications totals respectively 0.28 l/m², 0.57 l/m² and 0.41 l/m². Using densities of SG and IG silicone at 1.33kg/l and at 1.48kg/l for WS, this translates in a corresponding weight of silicone per m² façade. Knowing that the carbon footprint reported for a standard silicone [1] lies between 8 and 12 kg CO2eq per

kg of silicone sealant produced, depending on the formulation, we obtain corresponding kg of CO2 for each application per m² façade of 3.7kg CO2/m² for SG, 7.6kg CO2/m² for IG and 6.1kg CO2/m² for WS. The total carbon footprint for silicone per m² façade, considering SG, IG and WS can therefore reach up to 20kg CO2 eq/m². A building of 30.000m² using carbon neutral silicones represents therefore potential CO2 savings of up to 600ton eq, which can be avoided by switching to carbon neutral silicones. Depending on future evolution of CO2 industry, switching to carbon-neutral silicones for façades could result in significant savings for building owners [2]. Gaining access to Dow’s carbon-neutral silicones is straightforward. Project specific volumes to be consumed need to be disclosed together with project information and submitted to Dow. Please consult dow.com/ carbonneutralsilicones for more information. Material efficiency Material efficiency is an important aspect of a sustainable design. This approach focuses in the first place on building clever through preventing or reducing material usage which can help to further decrease the embodied carbon of a building envelope. To evaluate how bonded glazing, with or without carbon neutral silicones, can prevent or reduce material

intelligent glass solutions | spring 2022

EXECUTIVE BOARDROOM COMMENTARY

Table 1: Comparison of Ucw for different system configurations , at a fixed width of 1.3m

Model

Frame size (mm)

Glass thickness range (mm)

Structural

Thermal Uf (W/m²K)

System A SSG

63.5 x 190.5

6 - 25.4

Not listed

2.33

75 x 190.5

6 - 25.4

Not listed

2.73

63.5 x 165

6 - 25.4

1915Pa

1.93

63.5 x 190.5

6 - 25.4

1915Pa

2.50

System A Capped System B SSG System B Capped

resources, several state-of-the-art commercially available bonded (SSG) and mechanically fixed façade systems were compared from a structural and raw material usage. Representative systems for the APAC and North America (US) geographical areas were selected to cover a majority of projects worldwide. To isolate the benefit of the bonding itself, the systems were chosen in such a way that they both offer a bonded and capped version of the profile with very similar dimensions (in terms of sightline and depth) as well as very similar thermal performance (Uframe). Both APAC (System A) and US (System B) frame systems were unitized systems, selected so that both

A: capped

A: SSG

can accommodate the same wind load which was set at 2kPa, an average windload covering a majority of façade projects worldwide. The frames do not have specific features to cope with extreme loading like hurricane or blast loading. The dimensions for the façade unit were average and fixed at 1.3m width, for a vision height of 3m and spandrel height of 1m. As an illustration Figure 2 shows the standard vision mullions for the profiles A and B. More details regarding the mullion at spandrel level, the transom and stacked joint profiles are available upon request.

STANDARD VERTICAL MULLION VISION

Figure 2: capped and SSG versions of profile type A (left) and profile type B (right)

intelligent glass solutions | spring 2022

B: capped

B: SSG

To compare material use, a simple aluminium weight calculation was performed for the considered curtainwall (CW) unit dimensions (1.3mx4m). The structural adequacy of both systems was confirmed for stress and deflection requirements following American codes and standards [3, 4, 5]. Looking at the profile cross section drawings it is obvious that at equal capacity in structural loading, for the bonded and capped system, the latter will require a higher amount of aluminium, mainly due to the presence of the cap, and this was quantified to reach up to 15% for the considered systems. It is important to note that the here presented data is not intended to be a general conclusion but to be used as an illustration, highlighting that SSG systems can be designed to bring material efficiency benefits to the building envelope. A wide variety of façade systems are however available on the market and material savings may differ from the hereby presented results. For example, Europe favors toggle systems, with a complexity that requires a more thorough material analysis making it difficult

EXECUTIVE BOARDROOM COMMENTARY

to determine typical material savings. Similar to the unitized systems, the mechanically fixed European version will use more aluminium due to the cap. However, the toggle version adds additional material through the use of toggles and pockets. The pocket can be plastic or metal based, whereas the toggle is normally a metal alloy. Both are typically punctual inserts which should not exceed 30% of the perimeter and their presence should have a limited influence on the overall material use.

Reduced use of metal reinforcement in residential windows through bonding

Building further on this benefit, bonding can be used to transfer the glass rigidity to the frame and support consistent lightweight construction, leading to material savings and increased resource efficiency in all phases of the product life cycle. This concept has been successfully implemented in bonded PVC residential window

No replacement of gasket during lifetime of façade

frames, which only use steel reinforcements at larger loads or dimensions compared to a nonbonded window [6]. The composite behaviour of bonded assemblies is also used in the development of façade systems aiming to use less stiff frame materials than aluminium (e.g. fibre reinforced pultrusions [7]). Recognizing this benefit of bonding, the European curtain wall standard EN13830 [8] gives the possibility to work with lower profile stiffness (using slimmer profiles with less material and embodied CO2) provided the stiffening effect of the bonded façade elements is proven in the application through advanced calculation methods (e.g. finite element analysis). Advanced engineering methods optimize joint design: avoid Si over-dimensioning

In the above material usage considerations, only the aluminium reduction in SSG systems was intelligent glass solutions | spring 2022

EXECUTIVE BOARDROOM COMMENTARY

quantified based on the profile cross section comparison. However, for a full comparison of raw material usage, the quantity of silicone or EPDM gasket used could be assessed as well. Using the conventional joint dimensioning methods can result in some instances in oversized joints. Dow is however committed to developing advanced engineering methods which optimize constructive joint design and can reduce over dimensioning. As seen earlier, the lifetime of an SSG system is assumed to be 50 years, which also corresponds to the service life of a building. On the other hand, the service life of the EPDM gaskets for the dry glazed thermally improved system is assumed to be about 16.7 years. Gasket replacement may therefore be required during the lifetime of a façade. Due to the longer lifespan of the silicone components, the sealants can be used without need for replacement over the use phase of the building. As gaskets in dry glazed façade systems age over lifetime, air infiltration can increase more than is the case for the durable silicone wet sealed façades resulting in higher energy consumptions and consequently higher operational CO2 [9, 10], as will be discussed more in detail in the next section. As an illustration, it is possible to quantify the benefit of SSG façades from an embodied carbon viewpoint. A captive façade of 30.000m² with units of 1.3x3m², uses on average about 12-14kg/m² aluminium which results in 10-11kg/ m² for a bonded façade taking into account the 15% saving. Assuming an average embodied carbon of 15-17kg CO2eq per kg of aluminium, the SSG version of the façade, using carbonneutral silicones will save almost 1000 ton CO2eq. This is a conservative estimate, as savings linked to the use of carbon-neutral silicones instead of gaskets needing replacement during the lifetime of the façade are not considered. Benefits linked to the composite behaviour are not included either as these require project related analysis. Support energy efficiency Using carbon-neutral silicones and structural glazing in façades will contribute to optimizing resource efficiency and reducing embodied greenhouse gas emissions. However, silicones also influence the operational carbon emissions (handprint) by ensuring energy efficiency of the building envelope [10, 11]. The application of silicone sealants in construction can enhance the long-term resistance to degradation of buildings and can protect and extend a 48

Figure 3: isothermal lines for the standard vision mullion for the System A profiles

building's lifetime [12]. Silicone sealants and adhesives do have outstanding performance features when it comes to climatic resistance and weatherability. They allow flexibility for differential thermal expansion between bonded substrates or long-term adhesion durability to glass under temperature extremes and movements. Silicone sealants used for weatherproofing or bonding help to ensure airtightness and energy efficiency of the building envelope, as well as the use of energy saving multi-pane insulating glass units. Previous preliminary work by the authors had indicated the potential of specific SSG façades to help deliver a higher thermal efficiency compared to mechanically fixed façade systems [9, 10]. This study was updated by comparing the unitized façade systems described earlier. The thermal models were performed for each profile type, using the same double IGU with center of glass U value of 1.1 W/m²K. A representative warm edge spacer with linear thermal conductivity of 0.14 W/mK was used together with a silicone secondary sealing of 6 mm height. The thermal conductivities used

intelligent glass solutions | spring 2022

for EPDM, silicone, insulation or aluminium are the tabulated values as per ISO 10456 [13] and the thermal modeling was done according to EN ISO 10077-2 [14]. Based on the various dimensions and U-value for the frames, as well as the U-values for the glass or spandrel and corresponding linear thermal heat transmittance values Ψ the U value of the curtain wall unit (Ucw), consisting of the vision and spandrel elements was calculated [15]. The following Ucw values are obtained using a maximum width of 1.3m and heights of vision and spandrel varying between 1 and 3m. The benefit of SSG versus capped varies depending on the system and configuration between 10 and 25%. This consequently could result in potential savings in operational energy consumption. This exercise was repeated for the representative European toggle system. A triple IGU with a centre of glass value of 0.7W/ m²K and same thickness for both systems was used, to avoid influencing the U value of the frame and the Ψ values. In this case, both the toggle SSG and the mechanically fixed reached similar thermal performance results.

EXECUTIVE BOARDROOM COMMENTARY

Table 2: Comparison of Ucw for different system configurations , at a fixed width of 1.3m

Test Condition

Vision/Spandrel height (m)

System A SSG Ucw (W/m²K)

System A Capped Ucw (W/m²K)

System B SSG Ucw (W/m²K)

System B Capped Ucw (W/m²K)

Case 1

3/1

0.9

1.2

1.4

1.6

Case 2

2/2

1.1

1.4

1.5

1.7

Silicone structurally glazed façades allow energy efficiency targets be be achieved while optimizing material efficiency. More details of this study can be received upon request. Reuse and Recycle As explained before, optimizing the material and energy efficiency is crucial to ensure a sustainable design. One aspect which should however not be overseen is the end of life consideration and ensuring reuse and recycle can happen. Due to their small weight, silicone sealants are typically not the primary target of recycling of the façade. Instead the façade industry is assessing how bonded units can be dismantled and their high value components, such as glass or metal, reused. Silicone sealants should not prevent this step. At first sight, there might seem to be a contradiction between the durability of silicone bonded assemblies and the need for disassembly for repair or at end of life. But silicone bonding has specific advantages compared to other adhesives to enable maintenance, reuse and recycling. As opposed to more rigid bonding solutions (eg PU), silicones offer a good potential for disassembly at end of life [16]. The method developed for the dismantling of bonded glazing can further benefit from over 50 years of expertise in façade inspection, deglazing and repair exercises. Thanks to the durability of DOWSIL™ Silicone, it is possible to leave a layer of silicone on the substrate and use this layer to bond again on the frame, provided the origin of the original silicone and compatibility with the new silicone can be confirmed. Should a reuse of glass or frame not be desired then the silicone can be mechanically removed from the disassembled substrates. To close the loop of the lifecycle of a silicone in a façade, Dow is preparing to recycle the silicones reclaimed from the bonding and secondary sealing of the IGU. Several options to reintegrate these silicones into the production line process are currently being evaluated. This process will save raw material usage and also avoid the high energy required for the initial transformation of silica into silicone metal. Similar to other manufacturers, these studies will most

62 Buckingham Gate, London, BREEAM rating 'Excellent'

probably lead to the development of quality criteria requirements to allow injecting recycled silicone in the production. It is indeed crucial to ensure the origin and composition of the waste silicone. Build tomorrow with carbon-neutrality and Dow Building Science Dow’s investment into low carbon silicon metal manufacture, which embraces the advantages of backward integration, is just one example of our commitment to environmental, social

and governance. Our industry-first carbonneutral silicones program, verified by annual audits, represents an important step toward reducing the carbon footprint of buildings. This program is underpinned by the 50+ years of successful performance of our structural glazing silicones. Dow’s dedicated project support team, work in close collaboration with architects and consultants on a global basis, to offer support for engineering, design and sustainability.

intelligent glass solutions | spring 2022

EXECUTIVE BOARDROOM COMMENTARY

Please contact us to learn more about Dow’s carbon-neutrality program, documentation and project support tools: • Life Cycle Analyses (LCAs) • Third party verified ISO 14040:2006 and ISO 14044:2006 LCA conformance review statements • PAS 2060 Carbon Neutrality – QES documents with details • EPDs • Contribution of carbon neutral silicones to securing green building certification credits/ points • Product specifications for use in submittals • Digital project management tools with integrated carbon-neutrality services on specific projects Our innovative and performance-enhancing product technology showcase for sustainable and modern building design is available 24/7 at dow.com/buildingscienceconnect and documentation for project submittals may be downloaded at dow.com/submittalsemea. For further information, please visit dow.com/ carbonneutralsilicones. Literature 1.

Global Silicones Council, Silicon-Chemistry Carbon Balance, An assessment of Greenhouse Gas Emissions and Reductions, https://www.silicones. eu/wp-content/uploads/2019/05/SIL_execsummary_en.pdf, accessed 25/2/2022 2. https://www.ista.com/corporate/company/ content-world/co2-price-in-germany-what-canwe-expect/ accessed 25/2/2022 3. The Aluminium Association, Aluminum Design Manual (ADM): 2010 4. American Society of Civil Engineers, ASCE/SEI-7: 2016 - Minimum Design Loads and Associated Criteria for Buildings and Other Structures 5. Meinhardt Façade Technology, Curtain Wall Calculation of captive & SSG system report, 22 February 2022 6. Wolf A.T., Stiell J., Plettau M., Structural Bonded (Adhered) Window Systems, Conference Paper 7. Pascual C., Montali J., Overend M., Adhesivelybonded GFRP-glass sandwich components for structurally efficient glazing applications, Composite Structures, Volume 160, 15 January 2017, Pages 560-573 8. EN 13830:2015+A1:2020, Curtain Walling- Product standard 9. Carbary L.D., Albert F., A Thermal Modeling Comparison of Typical Curtainwall Glazing Systems, in Proceedings of Glass Performance Days (2007) 10. Carbary L.D., Hayez V., Wolf A.T, Bhandari M., Comparisons of Thermal Performance and Energy Consumption of Facades Used in Commercial Buildings, Proceedings of Glass Performance Days (2009) 11. www.feica.eu accessed 25/2/2022 12. Wolf A.T., Recknagel C., Wenzel N., Sitte S, Structural Silicone Glazing: Life Expectancy of more than

13.

14.

15. 16.

50 Years ?, in Proceedings of Glass Performance Days (2017) EN ISO 10456: 2007, Building materials and products — Hygrothermal properties — Tabulated design values and procedures for determining declared and design thermal values EN ISO 10077-2:2017, Thermal performance of windows, doors and shutters — Calculation of thermal transmittance — Part 2: Numerical method for frames Bauwerk, Thermal modeling Report reference dowcorning_211101_02b_en, 2022 Personal communication to the authors by Prof. Mauro Overend, TU Delft

Acknowledgement The authors wish to thank Meinhardt Façade Technology Singapore for the fruitful discussions on structural calculations

Valérie Hayez PhD Valérie Hayez is Global Façade Engineering & Architectural Design Engineer for High Performance Building Solutions at Dow, based in Belgium. She provides technical service to the design community, including façade system manufacturers, architects and engineers and communicates industry needs to Dow‘s Research and Development Community. Valérie has developed a broad expertise in façade engineering, including structural performance, fire safety, thermal or acoustic insulation and is active at standardization level. She holds an MSc and a PhD in Applied Sciences (electronics and optics) from the University of Brussels.

intelligent glass solutions | spring 2022

Disclaimer NOTICE: No freedom from infringement of any patent owned by Dow or others is to be inferred. Because use conditions and applicable laws may differ from one location to another and may change with time, Customer is responsible for determining whether products and the information in this document are appropriate for Customer's use and for ensuring that Customer's workplace and disposal practices are in compliance with applicable laws and other government enactments. The product shown in this literature may not be available for sale and/or available in all geographies where Dow is represented. The claims made may not have been approved for use in all countries. Dow assumes no obligation or liability for the information in this document. References to “Dow” or the “Company” mean the Dow legal entity selling the products to Customer unless otherwise expressly noted. NO WARRANTIES ARE GIVEN; ALL IMPLIED WARRANTIES OF MERCHANT.

Jayrold Bautista Jayrold Bautista is an Associate TS&D Scientist for Dow based in Singapore. He has over 15 years of experience in the built environment, providing technical, application and consulting expertise to stakeholders in the curtain wall and construction industry. He has helped many clients to achieve energy efficient, durable, well-designed facades for high-performance building projects with silicone and material science technology. Prior to joining Dow, he worked for a major façade consultancy firm and was involved in some tall building project projects in different parts of the world. Jayrold is a licensed civil engineer and has a degree in BS Civil Engineering from the University of the Philippines.

Reprints

EXECUTIVE BOARDROOM COMMENTARY

Whenever your company products or services are mentioned in IGS, whether it’s an article, case study or new innovation we can produce a tailor-made reprint for you to use in your future marketing and promotional campaigns. Reprints can vary from a single page to multiple page brochures.

#TheOriginalmyChoice

To order your reprints simply contact us at the following email address: nick@intelligentpublications.com or go to igsmag.com

REFLECTIONS FROM THE UN INTERNATIONAL YEAR OF GLASS 2022

Development and Trends D of Glass Innovation Under Global Climate Change

ue to frequent extreme weather and climate events brought about by continuous warming of the global climate system, countries around the world are attaching increasing importance to carbon emission reduction. The Chinese government, in an effort to fulfill the new requirements posed by “carbon neutral” development, has been committed to advancing green transformation of the glass industry and actively promoting the development of Building Integrated Photovoltaic (BIPV), glass hydrogen cycle and glass zero-carbon process reengineering, carbon dioxide capture, utilization and storage (CCUS) and other technologies. This article puts forward three proposals for the glass industry to embrace the low-carbon development strategy.

Prof. Peng Shou

EXECUTIVE BOARDROOM COMMENTARY

DECARBONIZE NOW! 62

intelligent glass solutions | spring 2022

THE NEXT FRONTIER IN GLASS FACADE INNOVATION

EXECUTIVE BOARDROOM COMMENTARY

Shanghai Bund, Shanghai, China. Photo by Edward He on Unsplash

Laura Karnath, AIA, NCARB, Senior Associate and Senior Enclosure Technical Designer, Walter P Moore and Sophie Pennetier, Associate Director, Special Projects, Enclos

intelligent glass solutions | spring 2022

Addressing the costs of carbon through the life cycle of buildings, from manufacturing, transportation, use, and less tangible social costs

EXECUTIVE BOARDROOM COMMENTARY 8

intelligent glass solutions | spring 2022

Design and engineer with less impact

intelligent glass solutions | spring 2022

Carbon Neutral Silicones in Façades – a window of opportunity

The first ever warm edge made of flexible structural foam.

Valérie Hayez, Jayrold Bautista 1 Angel Square, Manchester - The building was the first BREEAM rated ‘Outstanding’ regional office building in the UK and is EPC ‘A’ Rated. Courtesy of NOMA.

intelligent glass solutions | spring 2022

superspacer.com intelligent glass solutions | spring 2022

REFLECTIONS FROM THE UN INTERNATIONAL YEAR OF GLASS 2022

intelligent glass solutions | spring 2022

REFLECTIONS FROM THE UN INTERNATIONAL YEAR OF GLASS 2022

Flat glass:

leading the sustainability race Let’s seize the chance to trigger the much-needed virtuous cycle of decarbonisation This article is inspired from a speech given by Mr Philippe Bastien, Chairman of Glass for Europe, at the Palace of Nations in Geneve, for the Opening Ceremony of the International Year of Glass.

urope is now at a critical junction in shaping its energy transition, only accelerated due to the tragic events unfolding in Ukraine. This ongoing transition will demand hard-tosubstitute, transition-enabling EU flat glass in ever larger quantities up to 2050 and beyond. Europe’s flat glass industry needs to face today’s energy crisis, and, with adequate support, it will come out stronger to support Europe’s transition towards climate-neutrality.

intelligent glass solutions | spring 2022

REFLECTIONS FROM THE UN INTERNATIONAL YEAR OF GLASS 2022

Philippe Bastien at the Palace of Nations in Geneve, presenting at the Opening Ceremony of the International Year of Glass © Glass for Europe

Thirty years since the adoption of the first global agreement on tackling climate change, Europe’s transition to a sustainable, a lowcarbon, circular economy is now a reality.

An irreplaceable material in buildings Glazed facades and windows provide daylight inside buildings, offer views to the outside, ensure comfort and well-being to occupants,

A reality driven by the global Paris agreement and guided by ambitious policies like the European Union’s ‘fit for 55 package’ and ‘Green Deal’, aligned at the global level with the UN’s 2030 sustainable development goals. Beyond public policies, sustainability strategies are now central to every successful sector, and a central concern for many investors.

and create healthy indoor environments. No other material provides such transparency, energy-efficiency, safety, and durability at an affordable cost in the construction industry. The industry already has solutions today to help achieve tomorrow’s energy-positive buildings:

On track with sustainability Today, flat glass is on track when it comes to sustainability. The industry’s efforts in R&D have borne fruit. The sector is already contributing strongly today to a more sustainable, lowcarbon future, by providing the endlessly recyclable materials essential to renovate buildings, support the green mobility transition and help increase the share of renewable solar energy.

• High performance coated glass - significantly improving the insultation of buildings and avoiding unwanted heat-build. In Europe alone, its roll-out can help save nearly 100 million tonnes of CO2 from buildings. • Switchable glazing - that can adapt to solar heat and light depending on the weather and occupants comfort needs • Building Integrated PhotoVoltaics (BIPVs) - glazing that covers opaque parts of a building with integrated photovoltaic electricity generation, with its safety glass, different colours and finishes making it suitable for all building types • Transparent Photovoltaic glazing – advances in double and triple glazing mean that integrated photovoltaic electricity generation can also be integrated into building facades and windows.

These innovation efforts mean the solutions to meet tomorrow’s needs too are already available.

The industry is also continuing to invest to develop more durable and lighter glazing, as well as glazing enabling 5G transmission.

This is why, the European flat glass industry is fully engaged in this transition to a sustainable, low-carbon, circular economy.

intelligent glass solutions | spring 2022

REFLECTIONS FROM THE UN INTERNATIONAL YEAR OF GLASS 2022

A dynamic supplier to the automotive industry Flat glass is transformed into windshields, side windows, sunroofs, backlights and mirrors for the global automotive sector. Thinner safety glass reduces weight, and solar control glass minimises the need for air-conditioning. Both of these features help to reduce conventional vehicle emissions, as well as increasing range for electric vehicles. In the future, glass roofs with integrated photovoltaic cells could become mainstream. That means, for example, electric vehicles with their own photovoltaic electricity generation. All these solutions, including the digital glass inside vehicles, are also adapted to other means of transport, buses, trains, trams, and more, to contribute to safe autonomous and low-carbon transport.

Key to renewable solar energy It’s the low-iron glass and the self-cleaning coating technologies that allow maximum transparency in solar panels, helping maximise electricity generation. Thanks to glass, these solar panels are also made more durable. Mirrors redirecting light in solar concentrated power plants are also solutions coming from the flat glass sector’s portfolio. The flat glass industry contributes directly to renewable energy generation. intelligent glass solutions | spring 2022

REFLECTIONS FROM THE UN INTERNATIONAL YEAR OF GLASS 2022

Huge strides in reducing C02 emissions As we all know, any glass production is an energy-intensive process with resulting C02 emissions. Throughout the EU flat glass industry, engineers have worked very hard to reduce C02 emissions incurred during production. Since 1990, the industry has managed to reduce

emissions by an impressive 43% per tonne of flat glass. This outcome was achieved thanks to continuous improvements in EU manufacturing installations via three complimentary routes. First, via industrial innovation. Over the last

30 years, improvements to furnace design, construction, and operations were realised by using advanced furnace engineering, innovative materials and digitialisation. Second, by evolving in the energy mix. Again, over the last 30 years, the industry has ceased to use fuel oil to fire plants, together with employing electric boosting and raw material pre-heating. Third, through improving circularity. In the last decade, the industry has been able to use almost a third more recycled glass (cullet) as a raw material, by introducing collection schemes with transformers and recyclers. Thanks to these efforts, flat glass products, and in particular those used as glazing in buildings, deliver far more CO2 savings during their lifetime than are emitted in their production. Yes, that’s right, the flat glass industry is already a producer of CO2 avoiding products.

intelligent glass solutions | spring 2022

REFLECTIONS FROM THE UN INTERNATIONAL YEAR OF GLASS 2022

Glass is clearly on track today. And tomorrow? Let’s fast-forward to about 30 years from now, to 2050. If the policies like the European Union’s ‘fit for 55 package’ and ‘Green Deal’ come to fruition, Europe could be a sustainable, climateneutral economy.

Where does the flat glass industry fit into this future scenario?

mention the fact that 2022 is the United Nations International Year of Glass.

Clearly, it has a key part to play. It’s no coincidence that the leading scientific journal, Nature, recently described glass as “the hidden gem in a carbon-neutral future”. Not to

The key question is not ‘is the flat glass sector a key part of achieving a sustainable future’. The answer to that is a clear yes. The real question is: Can the flat glass sector provide all these indispensable products while cutting its own manufacturing emissions? Producing flat glass with minimal embedded CO2 As mentioned earlier, the industry has invested heavily in reducing C02 emissions in its energyintensive production process. The results are there to prove it. But Europe’s flat glass industry is not hiding away from its responsibility. It needs to go further and faster in slashing CO2 emissions as much as possible from flat glass manufacturing.

It’s ‘all hands on deck’ in Europe. At the company level, many Glass for Europe member companies have taken very ambitious commitments. For example, AGC has committed to an additional 30% cut in CO2 emissions by 2030, and climate neutrality by 2050.

intelligent glass solutions | spring 2022

REFLECTIONS FROM THE UN INTERNATIONAL YEAR OF GLASS 2022

It’s ‘all hands-on deck’ in Europe in the research labs and manufacturing sites too. This is where new production techniques are being researched and tested. For example, UK flat glass manufacturers, including Guardian Glass, are active parties to Glass Futures, a new glass research and testing centre with decarbonisation as one of its core areas of focus. It is no secret that flat glass manufacturers are looking into several routes, from greater recycling to new energy sources for firing furnaces to carbon capture and storage or use (CCSU). Greater recycling is an important route to cut emissions in flat glass manufacturing. For example, Saint-Gobain has publicly committed to increasing cullet in the batch up to 40% and is investing in glass treatment facilities to help achieve this. In parallel, there are research and trials to use new energy sources for flat glass furnaces: • for example, trials on hydrogen to power furnaces by NSG in the UK. • Work is also in progress on powering flat glass furnaces with a large share of electricity, biogas and other energy sources. • Hotoxy combustion or hybrid furnace solutions are also researched.

Investigations into the capture and reuse of remaining CO2 emissions via CCSU are also happening. It’s ‘all hands-on deck’ in Europe across the value-chain as well. The flat glass industry is looking into digitalisation and Industry 4.0 tools. These offer potential to optimise transport of flat glass sheets, minimise losses in processing sites and cut energy and CO2 emissions wherever possible. And, last but by no means least, it’s ‘all hands-on deck’ in Glass for Europe, the sector’s European

trade association. An ambitious 2050 vision was set by all members and partners, and the association’s activities are now fully geared towards realising this vision. Rising to the challenge while maintaining global competitiveness Technically, the challenge is great. But where it becomes most acute is in deciding how the industry can develop and roll out these completely novel manufacturing techniques while still maintaining its competitiveness in a global economy. Currently, despite facing higher regulatory and energy costs than its global competitors, the EU flat glass industry still manages to provide 85% percent of the EU demand for building glass. However, Europe’s demand for flat glass is expected to exponentially increase as Europe retrofits its buildings to decarbonise its economy. Meeting Europe’s future need for building glass will need several billion Euros in industrial investments at the cost of today’s state-of-theart manufacturing technologies. Of course, investment costs would need to flow at even higher levels in reality, considering that novel low-carbon manufacturing techniques will entail higher costs and risks, while old assets will also have to be depreciated. The flat glass sector, like any sector that competes in a global economy, needs the right support to stay competitive so it can help in delivering a sustainable, decarbonised future.

intelligent glass solutions | spring 2022

REFLECTIONS FROM THE UN INTERNATIONAL YEAR OF GLASS 2022

We need to unlock the virtuous decarbonisation cycle The flat glass sector, as a decarbonisationenabling industry in Europe, has developed a rapidly actionable, virtuous decarbonisation cycle. It’s imperative this cycle is triggered by concentrating emission reduction efforts on those sectors where solutions already exist for a massive decarbonisation, like buildings, transport and energy. Then, as new business opportunities are generated, the industry will need space to grow to respond to product demand so long as the manufacturing process is not yet largely decarbonised. This approach will generate the most rapid C02 emission reductions, higher economic activity, and further unlocking of investments in the research, pilot-testing and ultimately roll-out of novel clean manufacturing technologies.

The flat glass industry’s virtuous decarbonisation cycle has 5 main elements: Mainstreaming carbon-avoiding products, nurturing industrial competitiveness, attracting industrial investment, developing sustainable infrastructures, and rewarding innovations in clean technologies and products.

intelligent glass solutions | spring 2022

REFLECTIONS FROM THE UN INTERNATIONAL YEAR OF GLASS 2022

Mainstreaming carbon-avoiding products A starting point for a virtuous decarbonisation cycle is making carbonavoiding products mainstream. Net carbon-avoiding flat glass products are already available. Market forces alone do not ensure their uptake at a scale in line with the EU’s climate policy objectives. This is especially true in terms of building renovation.

growing internal demand by importing glazing products with a higher carbon footprint from other regions. It’s critical that Europe designs adequate competitiveness mitigation tools so hard-tosubstitute, transition-enabling products like EU flat glass remain affordable to consumers. © Glass for Europe

Markets are powerful tools in seeking climate impacts, but they need to be shaped to deliver on climate neutrality. Nurturing industrial competitiveness Transitioning to a carbon neutral economy can be a ‘growth engine’ for enabling sectors like flat glass. Nurturing industrial competitiveness means growth, jobs, investments and innovations can flow across the entire value-chain. A viable path to reducing CO2 emissions simply can’t involve meeting massively 60

intelligent glass solutions | spring 2022

Attracting industrial investment The combination of increased demand for lowcarbon flat glass production and a competitive manufacturing environment can unleash major investments in the flat glass industry. It’s essential that industrial and climate policies allow these industrial investments to materialise.

REFLECTIONS FROM THE UN INTERNATIONAL YEAR OF GLASS 2022

Developing sustainable infrastructures It is all the more essential that infrastructures and networks essential to low-carbon industries are in place rapidly.

Rewarding innovations in clean technologies and products Stimulating and rewarding innovation is the bread and butter of a virtuous decarbonisation cycle.

These essential infrastructure needs include: • Waste management facilities to collect and recycle end-of-life building glass: • biogas in sufficient quality and quantity for the sector to embrace this alternative source • a guaranteed supply of carbon-free electricity, independently of peak consumption time • Low-carbon hydrogen generation and networks • carbon capture transport networks and storage facilities Timing here is key, because all the technological routes to decarbonisation available today require infrastructure in place before investments can be made.

The virtuous cycle of decarbonisation will provide industrial actors the means and confidence to invest even more into R&D for net zero carbon solutions.

The EU flat glass industry, and its wider sector, is an important enabler in this radical transformation. A radical transformation that can only be successfully made if the right conditions are in place to still remain competitive in the global market throughout. This transformation to a new ecosystem is one that can only be achieved working together, across the full value chain, from suppliers to customers.

So, now let’s move towards conclusions. European authorities have made it very clear where they expect Europe, its society and its industry to be in 2050. The pathway to get there also start becoming clearer. Transitioning to this more sustainable, carbon-neutral future means deep reductions in energy demand for key sectors such as building and transport, and that the remaining energy consumed is carbon neutral.

The challenges and barriers that must be overcome are not to be under-estimated. Thanks to its impressive track record, one can be confident that the flat glass industry can and will continue delivering on sustainability.

Glass for Europe Glass for Europe is the trade association for Europe’s flat glass sector. Flat glass is the material that goes into a variety of end products, primarily in windows and facades for buildings, windscreens and windows for automotive and transport as well as solar energy equipment, furniture and appliances. Glass for Europe brings together multinational firms and thousands of SMEs across Europe, to represent the whole building glass value-chain. It is composed of flat glass manufacturers, AGC Glass Europe, Guardian, NSG-Group and Saint-Gobain Glass Industry and works in association with national partners gathering thousands of building glass processors and transformers all over Europe.

intelligent glass solutions | spring 2022

REFLECTIONS FROM THE UN INTERNATIONAL YEAR OF GLASS 2022

Development and of Glass Innovati Global Climate Ch Prof. Peng Shou

intelligent glass solutions | spring 2022

REFLECTIONS FROM THE UN INTERNATIONAL YEAR OF GLASS 2022

d Trends D ion Under hange

Shanghai Bund, Shanghai, China. Photo by Edward He on Unsplash

intelligent glass solutions | spring 2022

REFLECTIONS FROM THE UN INTERNATIONAL YEAR OF GLASS 2022

Preface For the past few years, continuous warming of the global climate system has been threatening the survival and security of mankind. In 2021, frequent extreme weather events around the world, such as Indonesia’s tropical cyclone in April and super rainfalls in Western Europe and China in July, have caused thousands of deaths and displacement of tens of millions of people. Countries around the world have taken carbon reduction measures to address the impact of climate change on human survival and security, and Glasgow Climate Pact signed in 2021 by the parties to the United Nations Framework Convention on Climate Change explicitly included the issue of coal and fossil fuels in the final decision of the Conference of the Parties and agreed to phase down coal as fuels. As a major global carbon emitter, China announced in September 2020 that “China aims to peak its carbon dioxide emissions by 2030 and strives to achieve carbon neutrality by 2060”. Glass plays an important role as a unique functional material in promoting energy transition and low-carbon transformation. The Role of Glass in Low-carbon Transformation The development of glass epitomizes the world’s history of science and technology progress. Glass is intrinsically linked to human civilization, as every progress of glass technology moves the world’s science and technology civilization forward. Facing the new requirements of “carbon-neutral” development, China is committed to promoting green transformation of the glass industry and puts forward the objective of pursuing “clean, zero-carbon, smart and efficient” development. China has clarified its low-carbon development path consisting of “core + key + foundation” technologies, in which the core technology refers to reconstruction of zero-carbon energy, the key technology focuses on reengineering of the zero-carbon processes in the glass industry while the foundation technology points to construction of a negative carbon system. Glass Supporting Zero-carbon Energy Restructuring According to BP’s Energy Outlook, under the zero-carbon scenario in 2060, photovoltaic and hydrogen will account for 35% and 8% of China’s energy structure respectively (as shown in Figure 1). Therefore, the combination of “photovoltaic + hydrogen energy” will be 64

World's largest integrated thin-film solar cell-building demonstration project in Anhui, China

crucial to the development of zero-carbon energy. Building Integrated Photovoltaic (BIPV) Thanks to Building Integrated Photovoltaic (BIPV) technology, power generation has become an integral function of BIPV buildings, paving the way to zero-carbon power generation scenarios. Development of the photovoltaic industry depends heavily on glass. For instance, crystalline silicon solar cells require photovoltaic glass as cover materials. Power generation glass and perovskite thin film solar cells require high strain point glass and transparent conductive glass respectively as substrate materials. China has achieved multiple innovative BIPV projects, including the construction of the 8.5th-generation TFT-LCD ultra-thin float glass substrate factory in Bengbu, Anhui Province (as shown in Figure 2a). Moreover, this factory is the world’s largest single building integrated with thin-film photovoltaics, with total installed capacity exceeding 10 MW and annual power

intelligent glass solutions | spring 2022

generation capacity reaching 11 million kWh. Its BIPV power generation addresses 40% of the entire factory’s electricity consumption, making it a true “lighthouse factory” with significant economic benefits and energy-savings achieved. Thanks to power-generation glass materials adopted, the entire system of National Speed Skating Oval in Beijing (as shown in Figure 2b) reduces carbon emissions equivalent to the annual CO2 emissions of nearly 3,900 cars. The Triumph Robot Intelligent Equipment R&D Center (the Center) built in Shanghai (as shown in Figure 2c) integrates prefabricated building materials, power-generation glass and advanced thermal-insulation building materials. The average power generation of the Center reaches 227,900 kWh per annum, saving 80 tons of standard coal and reducing 227 tons of carbon dioxide emissions every year. Green Hydrogen Energy Zero-carbon power includes solar energy and hydrogen energy. As hydrogen energy moves to the forefront of global energy competition, a key direction of zero-carbon development lies in the combination of photovoltaic +

REFLECTIONS FROM THE UN INTERNATIONAL YEAR OF GLASS 2022

hydrogen energy. In terms of hydrogen energy preparation, hydrogen production from renewable sources (green hydrogen) is the common development trend with a shared understanding achieved. Replacement of traditional fuels with green hydrogen offers the glass industry with a promising clean combustion technology —— an innovative technology pursued by Saint-Gobain, SCHOTT and other world-renowned glass companies with certain results achieved. In the future, upon accomplishing core steps in hydrogen storage and transportation, the construction of a “glass hydrogen cycle of preparationutilization-coupling” (as shown in Figure 3) will become the new direction of carbon emission reduction for the glass industry.

Glass Zero-carbon Process Reengineering To meet the requirements for “carbonneutral” development, zero-carbon on energy sources, raw materials and processes for glass production constitutes the core issue in glass technology system transformation. To illustrate, zero-carbon on energy sources focuses on utilizing green electricity and hydrogen as newtypes of energy resources. Zero-carbon on raw materials emphasizes the substitution with low-

Figure 1 China’s Energy Structure Forecast

intelligent glass solutions | spring 2022

REFLECTIONS FROM THE UN INTERNATIONAL YEAR OF GLASS 2022

Figure 2: Shanghai’s first building integration project of thin-film photovoltaics

carbon glass raw materials to reduce demands for high-carbon raw materials. Zero-carbon on processes highlights the use of digital twin, short-process manufacturing, material and energy recycling and other processes to reduce carbon emissions. Construction of a Glass Negativecarbon System Carbon dioxide capture, utilization and storage (CCUS) technology is an indispensable part of the global technology path to achieve “carbon neutrality”. According to The Energy Progress Report 2020 published by the International Energy Agency (IEA) and the World Bank, the carbon reduction effect of CCUS technology will be as high as 15% by 2070 (as shown in Figure 4), making CCUS technology an important part of carbon neutrality strategies of various nations. China’s glass industry attaches great importance to the development of CCUS technology and actively promotes the R&D and application of CCUS technology, which is mainly reflected in three aspects: (1) Clarify the R&D strategy and development direction of CCUS. (2) Increase support for CCUS technology R&D and demonstration. (3) Emphasize CCUS-related capacity building, international exchanges and cooperation. Figure 3: “Hydrogen cycle” of the Glass Industry

intelligent glass solutions | spring 2022

REFLECTIONS FROM THE UN INTERNATIONAL YEAR OF GLASS 2022

Suggestions for Global Glass Lowcarbon Development Facing continuous warming of the global climate system, three proposals are put forward for the glass industry to embrace the lowcarbon development strategy. Proposal 1: Leverage Sci-tech Innovations to Drive Glass Industry Development First, I call on global glass enterprises to establish a low-carbon innovation alliance. The alliance will carry out three missions with science and technology innovation as the core: 1) Formulate a global low-carbon development technology roadmap for the glass industry; 2) Carry out R&D for key, common and cuttingedge interdisciplinary technologies in the

Figure 4: Global Net-zero Emission Pathways by 2070

Solar business is glass business

intelligent glass solutions | spring 2022

REFLECTIONS FROM THE UN INTERNATIONAL YEAR OF GLASS 2022

glass industry; 3) Promote demonstration and application of new products and technologies for low-carbon glass. Proposal 2: Leverage Green Funds to Jointly Build a Harmonious Glass Ecosystem Secondly, I propose to set up a global glass industry green development fund, as green finance is the “accelerator” for low-carbon development of the global glass industry. The fund shall support interdisciplinary low-carbon R&D activities combining “glass + energy, glass + electricity, and glass + transportation” to open up a dynamic landscape with mutually enhancing activities. The fund shall also support small and medium-sized enterprises to cut emissions and promote decarbonization across the “whole supply chain”. The fund shall support developing countries to embrace low-carbon transformation and share green and low-carbon resources. In addition, the fund shall support scholars in the field of glass low-carbon development to conduct extensive communication and exchanges. The fund shall serve as a bride to connect the whole

world and contribute to the building of a harmonious global glass ecosystem. Proposal 3: Leverage Opening-up and Exchanges to Jointly Build a Beautiful Future for Glass Thirdly, I call on efforts to improve public science education on glass materials for a renewed understanding of glass by all mankind, strengthen talent exchanges to facilitate knowledge flow on a global scale, and promote cultural exchanges to emphasize the leading role of glass in ushering in a more beautiful life. Conclusions Given continuous warming of the global climate system, the glass industry urgently needs to accelerate its transformation to green development, and carry out science and technology innovation in Building Integrated Photovoltaic (BIPV), glass hydrogen cycle, glass zero-carbon process reengineering, and carbon dioxide capture, utilization and storage (CCUS) technology to achieve the goal of “carbon neutrality” at an earlier date.

National Speed Skating Oval, Beijing, China Empowering a high-tech and greener Winter Olympics

intelligent glass solutions | spring 2022

Prof. Peng Shou Prof. Peng Shou, academician of the Chinese Academy of Engineering (CAE), expert of glass new materials, is chief engineer of China National Building Material Group Co., Ltd., board chairman of China Triumph International Engineering Co., Ltd. and vice president of the Chinese Ceramic Society. Prof. Peng Shou has developed the worldclass 30μm flexible ultra-thin glass (UTG), the first high-generation TFT-LCD glass substrate independently developed in China, the first Chinese neutral borosilicate glass tubing for vaccines, the CIGS power generation glass with the highest efficiency in the world, and serials of glass new materials. He has been awarded with many prizes and received many weighty honors, including President Award of International Commission on Glass, Guanghua Engineering Science and Technology Award, Medal of Leadership in Advancement of Ceramic Technology of the American Ceramic Society, Ho Leung Ho Lee Foundation Science and Technology Innovation Award etc.

REFLECTIONS FROM THE UN INTERNATIONAL YEAR OF GLASS 2022

This article was originally published in the International Year of Glass 2022 book entitled “Welcome to the Age of Glass”. The book is written by glass industry pioneers and leaders and ties the wider glass industry firmly to UN sustainability aspirations. Some 13 chapters place glass at the center and edges of human activity. Read the full book here: www.saco.csic.es/index.php/s/XcPeY6mxGPGs8jy

intelligent glass solutions | spring 2022

REFLECTIONS FROM THE UN INTERNATIONAL YEAR OF GLASS 2022

REFLECTIONS ON REFLECTION GLASS IN ARCHITECTURE Sol Camacho 70

intelligent glass solutions | spring 2022

REFLECTIONS FROM THE UN INTERNATIONAL YEAR OF GLASS 2022

o speak about glass in architecture is to speak about the history of architecture of the past two hundred years, and that is a daunting task for an architect who has merely been studying this for a few years. I arrived at this subject almost randomly. My research on the subject grew as a derivative of my interest in the life and work of the ItaloBrazilian architect Lina Bo Bardi (1914-1992), who pioneered in the use of the material with two of her most iconic buildings, her own house in Morumby - today known as the Casa de Vidro (1951) (Fig.01) and the Museu de Arte de São Paulo Assis Chateaubriand (1968), also known as MASP (Fig.02). I arrived to live in São Paulo in 2011 and these two canonic examples of Brazilian Architecture were my introduction to the city; by studying about them I was able to connect with people and the history of the fascinating southamerican metropolis. These buildings condense the life and work of Lina - as she is locally known - and Pietro Maria Bardi (19001999), her husband, journalist and art critic founder of the MASP.

The couple arrived in 1946 from a torn-down Italy to a promising Rio de Janeiro and soon met Assis Chateaubriand (1892-1968), a media mogul who commissioned Bardi to found and direct an art museum in Sao Paulo in 1947, first inside the office building of Diários Associados on Rua 7 de Abril. With his critical eye and knowledge of European Art, Bardi built during the years one of the largest and most

important art collections in Latin America with a pioneering educational program that weaved the arts with other disciplines in the style of the Bauhaus. His knowledge and understanding of architecture had been acquired in his years as journalist in Italy, Bardi was an active member of modernist circles and exchanged letters to Le Corbusier, Walter Gropius and Richard Neutra. Italy at the time was under the facist regime that came into power in 1922 and modernism was in a delicate situation, if it enjoyed state sponsorship, it was also being persecuted by opposing factions. As there was no officialpromoted art, exhibitions and building commissions were disputed to gain favor with the state. While Giuseppe Terragni was working in his Casa del fascio de Como that became one of the icons of Italian Modernism and of glass architecture, Marcelo Piacentini consolidated through politics his position as leading architect with neoclassicism as the core architecture movement. The dispute over modernism and neoclassicism would extend even further than Italy. Brazil had open relations with Facist Italy due the populist dictatorship of Getúlio Vargas. If Bardi went to Brazil before the war to promote modernism to the Americas, Piacentini came to São Paulo on a diplomatic mission invited by the italo-brazilian industrialist Matarazzo family . Later political changes, such as a surprising pro-USA stance of Vargas in the event of the Second World War, would lead the Matarazzo to a pro-modernist stance with the sponsorship of the Museum of Modern Art of São Paulo in 1948 at the same

Fig. 02: Lina Bo Bardi's MASP ©Nelson Kon

Fig. 01: Lina Bo Bardi's Casa de Vidro. ©Instituto Bardi/Casa de Vidro

intelligent glass solutions | spring 2022

REFLECTIONS FROM THE UN INTERNATIONAL YEAR OF GLASS 2022

building of MASP at Rua 7 de Abril, and later to its location at Ibirapuera Park designed by Oscar Niemeyer. During the years 1938-1943 , in what can be interpreted as one of Bardi’s last contributions to italian critics before immigrating to Brazil, he worked in the magazine Il Vetro (Fig.03); but, he was forbidden by the regime to sign his text and his name wasn’t listed on the credits. Il Vetro was, as the italian name implies, a magazine around themes and uses of glass. In his contribution, Bardi wrote not only about technical uses of glass, but also wrote about glass architecture. Italian facism had tried to incorporate on its rhetoric glass as a metaphor 72

for the State, a metaphor which Terragni heavily leaned on as the new foundation of italian architecture, but ultimately lost to Piacentini’s neoclassicism. However, Il Vetro was one later addition to the ample debate of glass architecture as modern architecture, if not one of the last magazines to debate glass architecture before and during the Second World War. There is no easy answer for when the concept of glass architecture begins, contemporary critics tend to inscribe the beginning of glass architecture to the first decades of the 20th century; but Walter Benjamin in the 1920s studied a possible transition of glass as material to glass as

intelligent glass solutions | spring 2022

architecture in the 19th century. On the words of his notes of the incomplete project on the arcades of Paris: “Glass before its time, premature iron. In the arcades, both the most brittle and the strongest materials suffered breakage; in a certain sense, they were deflowered. Around the middle of the past century, it was not yet known how to build with glass and iron” Nevertheless, Glass has fascinated men over centuries way before any modern possibilities. Europe was dotted with colorful cathedrals, mirrored hallways and fogged greenhouses, and glass was used in artifacts and buildings

REFLECTIONS FROM THE UN INTERNATIONAL YEAR OF GLASS 2022

Figure 04: Bureau of Standards making extensive tests of glass building blocks. Washington, D.C. © Library of Congress, Prints & Photographs Division, photograph by Harris & Ewing, [reproduction number, e.g., LC-USZ62-123456]

Figure 03: Il Vetro magazine covers. ©Instituto Bardi/Casa de Vidro

all around the world without direct correlation to European arts and crafts. This fascination was always hindered by a limited supply and production of glass, a limitation that reduced the material to a luxury status. The Industrial Revolution unleashed new ways to mass produce glass in panes or common artifacts. Ample supplies and cheap production turned glass in a more affordable material to build even the simplest of structures (Fig.04). What Benjamin’s research argues is a change in the cultural and popular consensus around the use of glass with the construction and inauguration of Paxton’s Crystal Palace. While the arcades of Paris were a modern life

Figure 05: Bruno Taut's Glass Pavilion for the 1914 Werkbund © Unknown author, Public domain, via Wikimedia Commons

intelligent glass solutions | spring 2022

REFLECTIONS FROM THE UN INTERNATIONAL YEAR OF GLASS 2022

predecessor of the Crystal Palace, It was Paxton’s work to set the material of a modern architecture in Europe, correlated to the industrial progress of its time. Benjamin also argues that the 19th century glass architecture was correlated to velocity and temporary structures , since it was used mostly on railroad stations and exhibitions palaces , while the 20th century glass architecture was seen as stable and solid due a change of social perception of time. As new materials and structures principles were discovered and pioneered in the 19th century such as the glass curtain wall and reinforced concrete, mostly developed due the zealous work of engineers and pioneer architects, a search for a transcendental meaning for glass architecture pertains to art and architecture debates of the 20th century. Literature led the way before architecture, German author Paul Scheerbart was one of the first to attribute to glass a new spiritual sense and utopic possibility both in a manifesto and novels. Also the French authors André Breton and Louis Aragon would explore the glass at the arcades in surrealist novels. Scheerbart would be of great impact to Bruno Taut’s early works and publications on modern architecture, Taut’s book Alpine Architecture and the construction of the Glass Pavilion for the 1914 Werkbund ((Fig.05) were among the first works to present colorful glass as a medium of modern spirituality, architecture and industry. On the other hand, Breton and Aragon would be the bases of Benjamin’s critics of bourgeois privacity and defense for a transparent glass architecture of the proletariat, one that could not bear traces of ownership. Another major debate was in the meaning of the American skyscraper and how to translate the typology to Europe. While the USSR saw the skyscraper as a symbol of American capitalism, even with important unrealized projects such as El Lissitzky’s Cloud Iron, the German architects were among the first to correlate the stainedglass cathedral to the glass skyscraper. Be it on Bruno Taut’s Stadkroner , or on Walter Gropius’ Bauhaus Manifesto cover illustrated with Lyonel Feninger’s Cathedral, the skyscraper was understood as a modern spiritual equivalent to the historical cathedral . In the Americas, Frank Lloyd Wright explored the possibilities of both stained-glass and transparent glass panes, as a medium that 74

Figure 06: Mies van der Rohe’s Tugendhat Villa © User:Simonma, CC BY-SA 3.0 <http://creativecommons.org/licenses/by-sa/3.0/>, via Wikimedia Commons

could overcome classicism and achieve a true representation of the modern ways of the United States . The Larkin Building, famous for its glass skylights over the atrium, was deeply connected to a religious sense of work with its salomonic floor plan, carved inscription and a pipe organ. The later Johnson Wax Building had a more industrial and practical application of pyrex glass, still the architect had planned the installation of a pipe organ to the main office. On the other hand, Albert Khan was applying glass skylights and glass curtain walls to all his designs of Ford Plants to improve working conditions and reduce operation costs. 20th century industrial plants were almost a new form of architecture in themselves, one that demanded new technologies and material applications. If there was the skyscraper, there were also the industrial plant inserted on the debate of the modern cathedral, it is not casually that Peter Brehens’ AEG Factory was nicknamed “cathedral of work”.

intelligent glass solutions | spring 2022

Still, it was transparent glass over its colorful counterpart that became the general norm to modern architecture. As Scheerbart and Taut were both debating over the spiritual sense of modernity, Le Corbusier and Walter Gropius were focusing on the technical applications and social benefits. Glass was not only the material to build a new transparent society after the Great War, as Beatriz Colomoina’s X-Ray Architecture attest, glass was a material correlated to new sanitary measures against tuberculosis and other diseases. Sanatoriums were also a modern form where glass flourished, Alvar Aalto’s Paimio Sanatorium being one of the exemplary cases of the relation of modern architecture, health and glass; however the same could be applied in a private dimension to Neutra’s Lovell House and Mies van der Rohe’s Tugendhat Villa (Fig.06). What becomes clear from the 20th century debate is that there isn’t a single common

REFLECTIONS FROM THE UN INTERNATIONAL YEAR OF GLASS 2022

root or a primordial form of glass architecture. Even Paxton’s Crystal Palace, being the most prominent candidate to the position, is a parallel event to the arcades of Paris, which cannot be considered as isolated from the city. However, it is possible to search for traces and correlations between different works in their historical context. As such, the Crystal Palace was a development of the techniques applied on the construction of english greenhouses, and the arcade of Paris were consequential to the urbanization of paris from the late 18th century. While technology can partially explain the development of glass, it lacks means to explain the social reality behind glass architecture. Therefore, a typological study opens the possibility to create a nonexclusionary presentation of glass architecture, one that is capable of a critical reading of most works along a chronological distribution. Typology dictates both about constructed space and human interaction with space, if typology can be reduced to a list or diagrammatic distribution of spaces, it is meaningful only with human action on the space. Since glass architecture doesn’t have a single theoretical root, it also doesn’t have a single typological origin, opening the possibility to parallel typological developments. While it is straightforward with the arcades of Paris --because they can be traced as a origin point for the typological sequence of commercial galleries, department stores and even shopping

centers--, the Crystal Palace, being the first exhibition palace, is typologically in between two distinct functions and spatial dimensions. As it's possible to trace back the structure of glass and iron to the greenhouse and the later to stone and glass orangeries of royal palaces, from the Crystal Palace onwards there is a development of typologies focused on human interchange such as other exhibition palaces, modern expositive pavilions and convention centers. Modern Pavilions are another key typology to understand the development of glass architecture, many were constructed both as synthesis of an ideal and a proof of concept for architecture. All of them were built as temporary structures where architects experimented with new construction techniques and materials. Bruno Taut’s Glass Pavilion, Le Courbusier’s L'Esprit Nouveau Pavilion and Mies van der Rohe’s Barcelona Pavilion are some of the most iconic examples that explored glass in relation to architecture; but specially with Le Corbusier and Mies van der Rohe it is possible to note a development of a language of glass architecture expressed in a synthetic manner on their pavilions. The same can be said of Oscar Niemeyer and Lucio Costa’s New York Pavilion for the 1939 World’s in the context of brazilian modernism while the first major work, the Ministry of Education and Public Health, was still under construction. In the works of Mies van der Rohe, with both the Tugendhat Villa and Barcelona Pavilion, it is possible to note a correlation of modern pavilion and glass house. This correlation is also present in Le Corbusier and Niemeyer, among other early 20th century architects. As glass architecture consolidated itself as a modern language, the mid-century architects constructed a considerable amount of their glass houses in reference to early pavilions and glass houses. Philip Johnson and Lina Bo Bardi are prime examples of mid-century glass house architects.

Figure 07: Glass house’s bookshelves designed by Lina Bo Bardi © Instituto Bardi/Casa de Vidro

Still, this transition from the pavilion typology to the glass house typology is an ample one, the glass house or modern house are both a convergence of the experiences of the modern pavilion with the traditional bourgeois house due the clients’ social status. Therefore, the glass house possesses a social dimension in relation to its owners and easily typological study becomes a biography of the relation of intelligent glass solutions | spring 2022

REFLECTIONS FROM THE UN INTERNATIONAL YEAR OF GLASS 2022

house and owners. While Dr. Edith Farnsworth complex relation with Mies’ Farnsworth House is the most commonly know and welldocumented example, here we should turn our attention back to Lina Bo Bardi and Pietro Maria Bardi with their Casa de Vidro: The Bardi’s history is interchangeable with the Museum of Art of São Paulo, with Pietro being the first director of the institution and Lina being the chief architect of the building at Avenida Paulista. Before the present day museum, Pietro and Lina organized the first gallery of MASP at Rua 7 de Abril, while not in a proper sense a “pavilion” or glass architecture for the matter, it was an important experience on expography and museography, and Lina would adopt some solutions both in her glass house’s bookshelves (Fig.07) and in the new museum main exhibition hall . The Casa de Vidro was conceived as an extension of the cultural program of MASP, a centerpiece on a network of guest houses to be constructed for artists and curators that Bardi exchanged letters and critical essays. As such, the main hall glass of the Casa de Vidro

with its dining room, living room and office was designed as a room for this network of houses, facing with three complete glass facades the landscape of an unoccupied suburb of Morumbi in São Paulo. Lina’s glass house also kept a courtyard disposition of private spaces with a clear division between the owner’s rooms and service spaces, striking an interesting equilibrium of modern lifestyle and traditional praxis. Even when the network of guest houses was abandoned as a project, the main hall kept its concept as public space inside the private sphere. Pietro Maria's business as both director of MASP and art dealer made the place a diversified art gallery, and Lina’s collections of Brazilian regional crafts juxtaposed high arts with local craftsmanship. Trees and other plants created a green landscape around the house as Morumbi was integrated in the urban landscape as an elite neighborhood. Glass transparency that was once defined by the hills, horizon and sky became a close shadowplay of trees and nature (Fig.08). The MASP at the bustling Avenida Paulista also establishes a relation of art and landscape through glass in the main exhibition hall: as the

Figure 08: Reflections on the glass of the facade of the Glass House © Yghor Boy/Instituto Bardi

intelligent glass solutions | spring 2022

southwest facade opens a view to the top of the trees at Trianon Park, the northeast facades creates a vista to the axis of Avenida 9 de Julho and the historic city center. While most of the time the facades are not completely open to the landscape to protect the art from adverse effects of sunlight, the “glass easels” (Fig.09) supporting the paintings create a “collageeffect” inside the main exhibition hall, with the visual juxtaposition of styles and ages. Glass architecture came to build not only a new perception of space and art, but a new material reality for cities across the globe. From idyllic houses to monolithic towers, glass became a common shared experience of modern and contemporary lifestyle; but it also became part of a problem as much as a technical solution. As one of its advantages is transparency and heating through solar radiation, its widespread use disregarding local climate leads to an increasing consumption of electricity and resources through airconditioning machines, and both transparency and reflexivity contributed to the formation of urban heat islands and overall increase of a city’s temperature. For that, the glass

REFLECTIONS FROM THE UN INTERNATIONAL YEAR OF GLASS 2022

Benjamin, W., & Tiedemann, R. (1999). The arcades project. Cambridge, Mass: Belknap Press. p. 150 5 Benjamin, W., & Tiedemann, R. (1999). The arcades project. Cambridge, Mass: Belknap Press. p. 154 6 Other famous palaces of glass and iron besides the english Crystal Palace were the french Galerie des Machines and Grand Palais 7 Taut, Bruno. (2004). Bruno Taut, Alpine architektur : eine Utopia = a utopia. Munchen, Germany: Prestel. p. 36 8 Taut, Bruno. (2015) The City Crown. Surrey, England: Ashgate Publishing 9 This argument is better developed at Tafuri, Manfredo (1987). The Sphere and the Labyrinth: Avant-Gardes and Architecture from Piranesi to the 1970s. Cambridge, USA: MIT Press p. 125 10 Wright, Frank. (2008) Modern Architecture: being the Kahn lectures for 1930, Princeton, USA; Princeton University Press. p. 38 11 Colomina, Beatriz. (2019) X-Ray architecture. Zürich, Switzerland: Lars Müller Publishers. 12 The second concrete-enclosed gallery of MASP at Avenida Paulista resembles to a certain degree the space Rua 7 de Abril gallery with a museographic approach varying with curatorship. 4

Fig. 09: Lina and the “glass easel”. MASP main exhibition hall under construction. © Lew Parrella/Instituto Bardi

and glazing industry offers many technical solutions, and advances are now moving towards the construction of buildings that are energy neutral or even can contribute to the energy grid. So, If Walter Benjamin argues that in the first half of the 19th century it was still known how to build with glass in the heights of the Industrial Revolution, today one could say that in the first half of the 21th century we are undoubtedly expanding the knowledge on how to build an environment-aware glass in the age of climate changes. Glass architecture goes beyond the debate of ethics and aesthetics, it is the practical reality of cities and can be an integral part of an environmental solution to contemporary challenges. The International Year of Glass presents this unique opportunity to recapitulate the past two hundred years of glass architecture and think of a new future for the city of glass, to overcome its challenges and create new social perspectives. It allows architecture to go beyond the traditional constraints of the disciplinary field and be part of a coordinated debate about glass. To a certain degree, the International Year of Glass reinserts the debate of glass architecture in the 2020s and opens up the possibilities to review what was discussed only as utopies in the 1920s, perhaps even speculate what new typologies could develop from contemporary glass and new technological means of production. If there is urgency in solving pressing matters today, glass architecture should also concern with what comes of tomorrow as once it was seen as a clear future in itself.

Further reading Benjamin, W., & Tiedemann, R. (1999). The arcades project. Cambridge, Mass: Belknap Press. Benjamin, Walter. (1929) “Surrealism: The Last Snapshot of European Intelligentsia”, in Critical Theory and Society (1986), edited by Stephen Eric Bronner and Douglas Mackay Kellner, Routledge. Benjamin, Walter (1933). Experience and Poverty in Walter Benjamin: Selected Writings Vol. 2 (1999). US: Harvard University Press. Colomina, Beatriz. (2019) X-Ray architecture. Zürich, Switzerland: Lars Müller Publishers. Esmeraldo, Eugenia Gorini. (2020) AMER - a primeira América de Bardi : diário de bordo de P.M. Bardi (19331934). Unicamp, Tese Doutorado. Gropius, Walter (1965). The New Architecture and the Bauhaus. Cambridge, US: MIT Press Le Corbusier, Sirton P., Berton T. (Fall-Winter 2012) Glass the Fundamental Material of Modern Architecture in West 86th: A Journal of Decorative Arts, Design History, and Material Culture, Vol. 19, No. 2 Le Corbusier. (1964) When Cathedrals were White. US: Mcgraw-Hill Paperback. Tafuri, Manfredo (1987). The Sphere and the Labyrinth: Avant-Gardes and Architecture from Piranesi to the 1970s. Cambridge, USA: MIT Press Taut, Bruno. (2015) The City Crown. Surrey, England: Ashgate Publishing Taut, Bruno. (2004). Bruno Taut, Alpine architektur : eine Utopia = a utopia. Munchen, Germany: Prestel. Wright, Frank. (2008) Modern Architecture: being the Kahn lectures for 1930, Princeton, USA; Princeton University Press.

Sol Camacho Sol is an architect, urban designer, and curator leading RADDAR [www.raddar.org], an innovative practice of architecture, research and design that operates in São Paulo and Mexico City. Among the most outstanding projects that Sol leads are the Project for the Restoration, Adaptation and New Building of the Pacaembu Stadium, in São Paulo. In 2018, Sol was the curator of the exhibition Muros de Ar for the Pavilion Brazilian from the International Architecture Exhibition of the Venice Biennale. Since 2017, she has been Cultural Director of Instituto Bardi/Casa de Vidro [institutobardi.org], where she is responsible for exhibitions, cultural events and coordinator of Lina Bo Bardi's archive. Camacho has taught, written and lectured internationally on architecture, urban design and conservation at institutions such as PUC de Lima Peru, FADU de Montevideo Uruguay, Cornell, YALE, Harvard GSD, UMichigan en USA, among others.

References: Assis Chateaubriand owned and directed the media conglomerate Diários Associados and was a pioneer entrepreneur with the TV Tupi, the first TV in Brazil. 2 Piacentini designed for the Matarazzo family their corporate headquarters in Vale do Anhangabaú and their mansion at Avenida Paulista. The corporate headquarters was later acquired by the state and since 2004 is São Paulo’s town hall. The mansion at Avenida Paulista was demolished to give place to a shopping mall. 3 TENTORI, 2000, p. 150-152, apud ESMERALDO, 2020. 1

Sol Camacho. Photo by Daniela Toviansky

intelligent glass solutions | spring 2022

TRANSPARENT ARCHITECTURAL STRUCTURES

A Powerful Combination:

Glass and Modular Timber Okalux Glastechnik

intelligent glass solutions | spring 2022

TRANSPARENT ARCHITECTURAL STRUCTURES

The first of nine standardised sports halls has been built at the Lily-Braun-Gymnasium in Spandau. A total of three are being built in the same district; others will follow in the city centre, Lichtenberg, Reinickendorf and Steglitz. © Hans Jürgen Landes

erlin's first standardised sports hall has been built in modular timber construction at the Lily-Braun-Gymnasium in Spandau. The new building, which was designed by the architectural partnership scholl.balbach.walker, is part of the Berlin School Construction Offensive and is one of currently nine planned three-field sports halls. The highlight in all of the buildings is the powerful combination of glare-free and ball-resistant OKALUX K insulating glasses from Okalux Glastechnik, the specialist in daylight systems.

intelligent glass solutions | spring 2022

TRANSPARENT ARCHITECTURAL STRUCTURES

Berlin has grown rapidly over the past years and with it the need for school places. The Berlin School Construction Offensive – a senate administration investment project for education, youth and family, set to run for ten years – has set itself the task of renovating and enlarging the existing school buildings and constructing 60 new ones. In addition, nine three-field sports halls are currently being built in a standardised design – so-called standardised sports halls (German: TSH). Seven of them offer standing room for 60 people on a gallery, while two larger standardised halls have grandstands with seats for 199 spectators. The first to be built is the so-called TSH60 at the Lily-Braun-Gymnasium in Spandau.

Okalux achieved the extraordinary height of 5 metres by stacking capillary slabs and concealing the joints with additional glass fibre tissue. © Hans Jürgen Landes

Asymmetrical top hat profile in series A realisation competition was won by the design from the Stuttgart architectural partnership scholl.balbach.walker. In total, the new building has a floor area of around 1,700 square metres and offers space for a threefield sports hall with three equipment rooms, a multipurpose room and various function rooms as well as changing rooms, washrooms and toilets. The distribution to two auxiliary room zones with different depths along the longitudinal sides of the hall in favour of consistent ground-level use produces a striking contour in the cross-section that looks like a top hat profile and gets its individuality from the asymmetry. Symbolism and function merge

The facade has a vertical cladding of pre-greyed silver fir timber and is implemented with translucent glazing made of OKALUX K insulating glass. © Hans Jürgen Landes

intelligent glass solutions | spring 2022

TRANSPARENT ARCHITECTURAL STRUCTURES

into a single unit. The shifting of the changing room zone to the two gables also breaks the symmetry of the hall floor plan and zones the resulting diagonally opposite building recesses with two covered entrances: one to the public road, which is also accessible to local sports clubs and for competitions at the weekend, and one to the schoolyard for direct innerschool connection. The new building was constructed within a few months on a former football ground between Galenstrasse and Münsingerstrasse. That was made possible by the standardisation of the building elements and the high degree of prefabrication of the components, from the support structure to the building shell to the interior finishing. In this way, parallel to the standardised sports hall at the Lily-Braun-Gymnasium, it was also possible to commence work at other locations at short intervals - entirely in the spirit of a fast, costeffective and ecological construction offensive. Gymnastics with daylight During the planning of the hall with the 45 x 22 metre sports area there were many different requirements, including natural lighting with ball-resistant glare protection on the inside and outside. OKALUX K insulating glass with translucent, light-scattering capillary inserts provided a suitable solution here. Without additional glare protection devices, this ensures homogeneous, shadow-free illumination of the interior with daylight, which not only

In the choice of building materials, the new sports building impresses in terms of health and environmental compatibility and, with the help of the OKALUX K insulating glass, creates a pleasant daylight atmosphere in the sports areas and the gallery. © Hans Jürgen Landes

intelligent glass solutions | spring 2022

TRANSPARENT ARCHITECTURAL STRUCTURES

has a positive effect on the well-being of the sportspeople, but also reduces energy costs. The triple glazing with a low U-value of 0.8 W/m²K and g-value of 21% ensures both the required thermal insulation and the necessary sun protection at the same time. For pleasant visual comfort during ball sport competitions such as basketball and volleyball, 74 thermally insulating windows are integrated into the vertically divided wooden-aluminium mullion and transom facade above the protective walls along the entire longitudinal sides of the hall. In addition to the ball-resistant properties of the glass, OKALUX K also convinced the 82

architects through the individual tailor-made production in sizes of 1147 x 4880 and 1120 x 4880 millimetres. "With the daylight system from Okalux we have been able to realise continuous glazing for the area between the protective walls and the hall ceiling that blends harmoniously into the 1.25 metre-wide facade grid with no disturbing horizontal subdivision," says Michael Walker. The fact that fast manufacturing time and quality are not contradictory is also shown by the good recyclability, durability and maintenance-free use of the selected OKALUX K insulating glazing.

intelligent glass solutions | spring 2022

Okalux Glastechnik From its very history, OKALUX has a deep understanding of daylight planning. The company's entry into the forward-looking insulating glass sector in 1967 was a lightdiffusing and insulating capillary sheet made of acrylic (PMMA), which was originally developed as a hollow fiber for the textile industry. Since then, the German company has been producing and developing aesthetically and energetically sophisticated daylighting systems under the company name OKALUX - a combination of the initial letters of the department name and the Latin term for light. As an independent brand within the Glas Trösch Group, OKALUX shares the reliable values and quality standards of the Swiss family-owned company.

TRANSPARENT ARCHITECTURAL STRUCTURES

It is evident that the solutions are complex and multifaceted, and that in the fight against climate change, we need to attack from multiple angles. Driving circularity, adaptive reuse, incentivising the adoption of ‘better technology’, stimulating and rewarding “green” innovation, nurturing industrial competitiveness, creating a culture of transparency, collective urgency and accountability throughout the entire supply chain and all stakeholders are key considerations that have been explored in the pages of IGS Magazine. In the second chapter of this issue, you will be introduced to more exemplary minds and projects, including the unique and sustainable glass veil façade for Spencer Place in Dublin. We discover, in detail, the mold-breaking Glass Futures and their research into low carbon alternative fuels for glass furnaces. Last, but by no means least, Klaus Lother, has the “Glass Word”; the Permasteelisa Group CEO imparts unparalleled wisdom as we delve into his thoughts on climate change, emerging technology and gain exclusive insights into upcoming projects from the prolific group.

To come: Amber Gupta

“While ROI and payback are critical to all decision-making, sustainable and environmentally friendly solutions to decarbonise a project should not be traded off against improving the bottom-line”

Page 90

Aston Fuller

“In reading about the impacts of climate change and shifting geopolitical sands, what is very evident is that the events happening around us apply more pressure to the system and force it to adopt a new footing.”

Page 120

Johannes Novy

PLENTY MORE TO COME

The first half of this Spring Edition is a testament to the industry’s steadfastness and drive to build a sustainable future for our planet. The clear vision and holistic approach to decarbonisation outlined in the preceding pages has uncovered critical issues that we, as a collective, need to address. As much as questions have been answered, the authors leave us with plenty to think about.

“When the built-to-last principle proves impractical, however, buildings designed for a shorter lifespan can still be made more sustainable, provided a whole-life carbon approach is adopted and the components and materials used are easy to dismantle and reuse”.

Page 140

This is IGS – Nothing more, nothing less…NOTHING ELSE Image credit: No 4 St Paul’s Square, Liverpool, photo courtesy of English Cities Fund. Grade A, BREEAM Excellent rated office building.

intelligent glass solutions | spring 2022

TRANSPARENT ARCHITECTURAL STRUCTURES

intelligent glass solutions | spring 2022

TRANSPARENT ARCHITECTURAL STRUCTURES

A unique and sustainable glass veil façade for Spencer Place

Andreas Scheib, Chief Communication Officer, Glas Trösch Group

intelligent glass solutions | spring 2022

TRANSPARENT ARCHITECTURAL STRUCTURES

or some time now, Dublin’s North Wall Quay on the Liffey has been home to one of Ireland’s spectacular façade projects. Triangular laminated glass panes from the Swiss glass specialist Glas Trösch create a veil-like second skin for the building in question, which is part of the ‘Spencer Place’ urban campus. The area as a whole consists of four interconnected blocks and offers plenty of space for office and leisure use. The project reflects the highest sustainability standards in terms of both the production of glass and its ongoing use.

For over 20 years, the Dublin Docklands Development Authority has been looking to promote the social and economic development of the Dublin Docklands, which once were working docks, in the heart of the Irish capital. And with some success, as the district has become increasingly lively thanks to 11,000 apartments and 40,000 jobs. The area’s architectural profile has already been enhanced by some noteworthy construction projects. These include the Grand Canal Square Hotel by Manuel Aires Mateus, the Grand Canal Theatre by Studio Daniel Libeskind, and the Convention Centre Dublin by Kevin Roche. This prestigious

intelligent glass solutions | spring 2022

riverside promenade now also features the glass façade of the urban Spencer Place campus by Henry J Lyons Architects. High-tech solution for ‘Silicon Docks’ The façade combines a listed Victorian building with a glass veil-like shell, while the campus behind it will be home to a software company. And with a number of high-term firms already having their European headquarters nearby, Dublin Docklands have also become known as ‘Silicon Docks’. But the kind of firms in situ already are just one of the reasons the Spencer Place project looks set to attract innovative

TRANSPARENT ARCHITECTURAL STRUCTURES

companies. Other selling points include its good transport connections and how the building meets sustainability standards. Dublin architects Henry J Lyons have come up with an energy concept that fulfils the requirements for dual LEED v4 Platinum and Net Zero Carbon certification. This incorporates both a renewable energy supply and the use of intelligent construction materials. Brilliance with a positive environmental impact The glass façade that adorns the riverside is the biggest factor in the striking visual impression

intelligent glass solutions | spring 2022

TRANSPARENT ARCHITECTURAL STRUCTURES

created by the campus. The triangular shapes form a geometry that diffracts sunlight in dynamic ways, while the SILVERSTAR WhiteShine T coating creates silvery-white reflections. In addition, the façade serves as a second skin and its soundproofing effect shields the interior from the docklands bustle outside – while creating a productive working atmosphere with a lively outlook. The glass veil façade also provide further sun protection and stops the interior heating up, which has the

added benefit of reducing energy requirements even more. Even at the manufacturing stage, the glass façade meets the highest sustainability standards. Glas Trösch adopts environmentally friendly production methods and uses highly efficient melting furnaces and heat recovery. About a quarter of the energy requirement at the float glass plants is covered accordingly. Local raw materials mean short journeys,

intelligent glass solutions | spring 2022

exemplary fragment-retrieval systems reduce raw material requirements, and other logistics measures reduce the carbon footprint during production and help construction projects deliver a positive environmental impact. The Swiss Glas Trösch Group is a dynamically growing family business that has been dedicated to glass in all its fascinating diversity for over 100 years. During this time the company has developed from operating a

TRANSPARENT ARCHITECTURAL STRUCTURES

single workshop in the local area to now being Europe’s biggest glass manufacturer and processor, employing around 6,000 people across 70 locations. Swiss quality, excellent service and reliable partnerships are just some of the core values. Furthermore, it is the goal to reconcile social benefit, ecology and economy in the best possible way and thus also to protect future generations. This is what the guiding principle "Green for Generations" stands for.

Andreas Scheib Andreas has worked for Glas Trösch for almost 20 years in various positions. After completing a Master’s degree in corporate communications at the University of Applied Sciences Northwestern Switzerland, he became the Group’s Chief Communication Officer in 2019. In this position, he is responsible for marketing in the architectural glass business unit. In addition to his professional tasks, Andreas engages in voluntary work for an organisation that offers free-time activities for teenagers in the region, thus preventing them from excessive media consumption.

intelligent glass solutions | spring 2022

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

The Building of the Year 2018: The Life Sciences Building at the University of Washington, designed by Perkins+Will, benefits from first-of-its-kind Onyx Solar photovoltaic fin system on the curtain wall. Credit: © Onyx Solar Energy

intelligent glass solutions | spring 2022

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

and the breakthrough building material that’s making it happen today

he year 2018 saw the completion of a beautiful building in the same city of the USA where another excellent project was delivered only a few years before, by the same architect, for the same client. Both buildings were comparable in size and the purpose they were built for.

Amber Gupta, Onyx Solar

Excellent design for both utilised a range of green building strategies that saw them receive LEED Gold certification. The projects were highly sustainable, meeting the stringent environmental requirements they had set out to achieve. The client was pleased with the outcome. However, there was a difference.

intelligent glass solutions | spring 2022

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

Transforming facade into energy harvesting array: The Life Sciences Building (LSB) benefitting from using Onyx Solar photovoltaic glass on facade. Credit: © Onyx Solar Energy

Fast forward a few years, one building went almost unnoticed, while the other is still making headlines; with people still talking about it today. It has become a ‘must see’ architecture for people visiting the area. It won numerous awards, including the Best Multi-Functional Curtain Wall Project Award at the Sustainable Building Awards 2018 by Build Magazine, the Sustainability Award by CABE (Chartered Association of Building Engineers of UK) at the 2019 Built Environment Awards, and the COTE 2021 Top 10 Sustainable Awards in the USA.

Credit: © Onyx Solar Energy

What was the difference? Besides having excellent teams of architects and developers involved, the winning project had incorporated a unique, first-of-its-kind innovation in the USA. It featured a transparent photovoltaic (PV) glass fin, turning the aesthetically pleasing design into a renewable, solar energy harvesting, vertical curtain wall. Later in this article we will find that, in using this technology, any building surface (walls, façades, curtain walls, windows, skylights, roofs, floors) can produce free and clean energy. 92

That is not all. The project also won the prestigious Building of the Year Award 2018 by the Daily Journal of Commerce, finishing ahead of some of the most iconic buildings ever built, including The Space Needle, F5 Tower/ The Mark and the Amazon Spheres in Seattle, Washington.

intelligent glass solutions | spring 2022

What is exciting about the technology used by the winning project, the Life Sciences Building (LSB) at the University of Washington (UW), are the ramifications for future builds. A city’s largest glass buildings could be transformed into giant solar panels, while looking indistinguishable from a standard glass-clad building.

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

The PV curtain wall delivered numerous benefits. It offered improved thermal performance by providing shading in the summer; helps generate enough energy to power a good portion of the building's energy usage; reduced operational costs; unlocked environmental and operational benefits not attainable using traditional glazing; reduces emissions by 333 tCO2 (over a calculated period of 35 Yrs.). And, notably from a financial perspective, it offered a fantastic payback period of fewer than three years. Onyx Solar Energy innovated, designed, and manufactured the smart PV glass, a unique solution that’s helping us transform real estate globally. We received Build Magazine's Best Building Photovoltaic Glass Provider 2018 award for this project. This story has and will be repeated worldwide. Thousands of new buildings, from small residential to high-rise, and renovation projects (of existing building stock) will be delivered. There is enormous environmental potential that is waiting to be tapped into by innovative technologies like Onyx Solar PV glass.

Architects and developers face unique challenges to minimise the negative impacts of architecture on society, the environment and the economy. When key design objectives are applied, from the planning phase to operations and maintenance, a choice in building material can make a tremendous difference. It can turn the project from a net-user of energy to a net-producer. Indeed, we have not yet finished innovating the most promising renewable energy solution on earth - solar energy. By the end of this article, it will be evident that beautiful glass buildings can be more sustainable than ever before and generate their own energy without compromising aesthetics and energy performance. Climate Change is Happening Right Now The impact of climate change is becoming increasingly dire and deadly with extreme conditions such as wildfires, flooding, storms, and droughts that have impacted millions of lives. The challenge of reducing our global emissions from 51 billion to zero is the "greatest challenge humankind has ever faced".

The latest annual sustainability report by RICS and the World Built Environment Forum reveals that the built environment is still not moving fast enough to decarbonise building stock. In a sector responsible for more than onethird of all emissions, where we have not yet minimised the impact of existing builds, and where scores of new developments are soon to join the ranks (to the tune of an equivalent New York City every month for the next 40 years), the prospect of net-zero is challenging to say the least. The good news for professionals working in the built environment, is that they can drive change. Critical decisions in building materials, waste, energy sources, water, health enhancement in buildings, more cost-efficient and attractive design options will have a significant impact. Recently, US Climate Envoy John Kerry said that solving climate change will require "technologies we don't yet have", which holds validity to some extent and certainly adds to the concern. It is also true that numerous (existing) sustainable market-ready breakthroughs that can transform industries are not always obvious to decision-makers.

Credit: © Onyx Solar Energy

intelligent glass solutions | spring 2022

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

According to SOM and the National Geographic article, the energy-efficient and sustainable building material of the future should have the following key features:

1. Allow renewable energy generation from the sun using buildings walls, windows, and other surfaces. 2. Boost the energy performance of the building envelope. 3. A transparent material allowing natural light into the building, mitigating reliance on artificial lighting. What if a building material already exists that can match these criteria? Moreover, what if it is not just an idea but a proven solution used in hundreds of projects by the most renowned architects and developers across the globe?

The work I have been involved with within the built environment has given me optimism that technology and innovation can make a difference if we invent and deploy them fast enough. I am privileged to share a new paradigm of solar renewable energy and push the agenda of leveraging innovation to build sustainable buildings of the future, today. Imagining the building material of the Future More buildings will require more energy to accommodate an estimated 6.7 billion people

living in cities by 2050. How will these buildings be constructed? Is there a way to address the increase in energy use and energy-related greenhouse gas emissions simultaneously? The National Geographic Magazine 'Cities' (April 2019 Ed.) published an article attempting to answer the key question "How to build cities of the future (2050 and beyond)?" In his article 'Cities of the Future', Peter J. Kindel of SOM (Skidmore, Owings & Merrill Inc) provides an insightful and futuristic vision for future cities, ecosystems and energy-smart buildings.

At Onyx Solar, located in Spain, we have developed the building material envisioned in the preceding paragraphs. The futuristic idea of generating energy from a building’s walls and windows is no longer science fiction. Introducing Onyx Solar transparent photovoltaic (PV) architectural glass for buildings. We have developed transparent photovoltaic glass (not to be confused with solar panels) – the only building material that replaces standard glazing and embeds a solar panel's energy generation capability into any building surface, without compromising aesthetics and energy performance. We have

The Building Material of the Future: The National Geographic Magazine 'Cities' (April 2019 Ed.) published the work of SOM (Skidmore, Owings & Merrill Inc) and the National Geographic team envisioning the cities of the future (2050 and beyond). It indicated some critical features of sustainable building materials of the future. Credits: @National Geographic @SOM

intelligent glass solutions | spring 2022

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

Think Vertical: A new paradigm in solar renewable energy is reshaping our city's unutilised vertical built surfaces into a solution for climate change. Credits: ©Onyx Solar Energy

turned city skyscrapers into vertical generators, delivered more than 400 projects globally, from tall buildings to residential projects, in 50 countries covering all industries (Government, Healthcare, Commercial, Transportation, Retail, Corporate and Education) and building typologies. With sustainability at the forefront of most activities today, our solution helps our clients not only reduce emissions and meet net-zero goals, but also future-proof their projects. World renowned brands and asset owners have already benefitted from this solution including: Coca-Cola, Microsoft, Heineken, Pfizer, Hewlett Packard, McDonald`s, ING, AXA IM, to mention a few. We have worked on iconic developments with renowned architects/partners globally such as Foster + Partners, SOM, Perkins+Wills, Gensler, Skanska and HB Reavis. "Most Innovative Glass": A Breakthrough Engineering In 2015, Onyx Solar Low-E transparent PV glass received the "Most Innovative Glass" award from the National Association of Glass in the United States and the Association of Doors and Windows Dealers at the prestigious Glass Magazine Awards. While the world also focuses on solving the “cement and steel problems”, there is glass. An Urban Green Council (UGC) report stated that "todays glass building envelopes will contribute to carbon emissions long into the future unless we curb our appetite for them". We beg to differ! Today, we have high-performance glass available in the marketplace that provides better insulation and daylighting to reduce energy loads and offer optimum energy performance.

But given the current climate crisis, can we do any better? As some “environmentally-conscious” architects move away from using too much glass under the assumption that it is unsustainable, this breakthrough material, a marriage between PV panels and high-performance architectural glazing, solves this problem for the construction industry. Consistent innovation has enabled Onyx Solar Energy to offer a unique solution unlike anything available in the marketplace: • A building material that replaces standard glazing and embeds a solar panel's energy generation capability into any building surface (among other architectural applications) without compromising the building's aesthetics, energy performance and maintenance. • Boosts the energy performance of the building envelope, with exceptional Energy Rating performance, thanks to the optimised balance of solar gain (g-value) and thermal insulation (U-value). • The highest rating in fire safety standards (Class A) • Transparent photovoltaic glass lets natural light into the building, so we don't rely as much on artificial lighting. • Offers excellent thermal & sound insulation (0.6 W/sqmK) while filtering 99% UV & up to 95% IR, offering comfort indoors. • A building material that pays for itself with an attractive ROI and payback period demonstrated in projects across five continents. A New Paradigm of Solar Renewable Energy: Think Vertical Historically, solar panels have been the ‘go-to’ in renewable energy sources. However, relying

on land (solar farms) and building rooftops, many of which are unsuitable, creates limited opportunities. Arguably, their greatest pitfall is where to put them as they render a space almost unusable. In addition, limited available land for solar panels that would generate sufficient energy for a country’s needs, make such a solution unviable. To illustrate this, Singapore would require 830%, Hong Kong 213% and Bahrain 156% of their land for any meaningful energy generation (Source: Finder. com). As cities get denser and energy demands increase, we need innovation. And there is a potential solution in plain sight, you just need to know where to look. We have vast building surfaces in the form of facades, curtain walls and windows. These vertical surfaces in our cities’ buildings have remained unused, with little to no contribution to solving the climate challenge. What if we could utilise these surfaces to harvest renewable solar energy and unlock their full potential – turning net users into net producers of energy? Well, we can. With the latest technology, we can build beautiful looking glass buildings and tall skyscrapers that are future-proof. Whatever future buildings may look like, whether floating in the sky or constructed by AI, one thing is for sure; they must be entirely energy sufficient. Given the need of the hour, not utilising the immense vertical building surfaces to our advantage is not an option. It will be unsustainable to keep building our future cities and only rely on far afield solar farms to power them. We have not had the right technology to make this happen until now.

intelligent glass solutions | spring 2022

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

Transforming Glass Buildings from Net-Users to Net-Producers: Case Studies While high-performance glazing is a good choice for our city’s skyscrapers, it may not be enough. Given ambitious climate goals, meeting the minimum requirements is insufficient. In the following case studies, we delve into the benefits of PV panels and the iconic projects that have utilised them:

THE HIGHEST-SCORING LEED PLATINUM OFFICE BUILDING IN EUROPE, 2021: GIOIA 22 Tower in Milan, Italy, may look just like any other glass building, but thanks to Onyx Solar photovoltaic glass, the façade is producing enough energy to power 300 average residential homes. Also called "shard of glass", it is the largest building in Italy designed and constructed according to Near Zero Energy Building standards (NZEB), aligned to the EU 2°C decarbonisation target by 2050. Project designed by Pelli Clarke & Partners and developed by COIMA.

PHOTOVOLTAIC SKYLIGHT FOR NOVARTIS PHARMACEUTICAL HQ, NEW JERSEY, USA: Designed by Rafael Viñoly, the photovoltaic skylight, measuring 2,500 m2 with a power capacity of 340 Wp, generates over 273,000 kWh per year, reducing nearly 185 tons of CO2 emissions. Credits: © Onyx Solar Energy

intelligent glass solutions | spring 2022

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

ICONIC BUILDINGS IN DUBAI EXCELS IN SUSTAINABILITY: Dubai Electricity & Water Authority (DEWA) R&D Centre and Dubai Frame used highly innovative coloured photovoltaic façades developed to meet the project needs, allowing these buildings to generate energy without compromising aesthetics and energy performance. Credits above: @Onyx Solar Energy

THE LARGEST INTEGRATED PHTOVOPTAIC FAÇADE SYSTEM IN CYPRUS: Cyprus International University’s Science and Technology Centre is a unique project installed approximately 1,000 m2 of PV glass to reduce HVAC energy demands by almost 43% with an IRR of less than three years. Credits: ©Onyx Solar Energy

intelligent glass solutions | spring 2022

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

AN AWARD-WINNING OFFICE BUILDING: Culver City Creative (C3), designed by GENSLER is an award-winning project that integrates a photovoltaic curtain wall of 743 m2 (8,000 sq. ft). This aesthetic architectural solution will generate 30,976 kWh and will prevent the release of 20,754 Kg of CO2 into the atmosphere every year. Credits: ©Onyx Solar Energy

THE FIRST SPORTS FACILITY TO RECEIVE GOLD RECERTIFICATION: The NBA Miami Heat Stadium, USA, also known as the “American Airlines Arena”, used circular photovoltaic skylights preventing the release of 20 tons of CO2 into the atmosphere, contributed to becoming the first sports and entertainment centre to obtain the LEED Gold recertification. Also received Most Innovative Photovoltaic Glass Project 2016 by Build Magazine. The image in the inset is © Onyx Solar Energy Credits: ©Onyx Solar Energy 98

intelligent glass solutions | spring 2022

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

McDONALD’S FIRST NET-ZERO RESTAURANT: The first of its kind amongst the fast-food giant's 40,000-plus restaurants, the one at the Walt Disney World Resort in Florida is utilising several traditional green technologies; however, added in the mix is innovative Onyx Solar transparent photovoltaic glass for the skylight helping maximise the generation of on-site renewables. Credits: ©Onyx Solar Energy

How to reduce emissions: Efficiency is key, but renewable is critical The three strategies of addressing emissions from energy consumption in buildings can be explained by the Energy Pyramid:

EFFICIENCY IS KEY, BUT RENEWABLE IS KEY Credits: Image courtesy of www.greenrevolutionltd.com

The first steps to energy conservation include: changes in the behaviour of occupants (in terms of energy consumption), zoning of heating and cooling units, building envelope/ fabric choice, insulation and ventilation strategies. Whilst energy efficiency approaches involve choosing suitable heating and cooling equipment as well as ensuring energy efficiency through low energy lighting such as LEDs, adequate external lighting and the use of motion sensors, monitored by smart meters (to mention a few). Addressing renewable energy generation as a key opportunity for tackling energy-related emissions is a crucial step to a sustainable future. The RIBA 2030 Climate Challenge notes maximising on-site renewable energy as one of the key strategies to achieving ambitious onsite energy goals. On-site energy intensity reduction is essential. Numerous industry experts and research points to the fact that decentralised renewable generation is the future; it is the most reliable, cost-effective and sustainable option. However, in the past we have failed due to a lack of innovation in achieving viable solutions in our

city’s skyscrapers. The Citi Tower, for example, may be able to source all renewable energy from far afield solar farms; however, the best outcome would be for the façade of the building to pay for its own electricity and take free and clean energy from the Sun and not the grid. Rebuild or retrofit? Decarbonising existing building stock Retrofitting an existing building can often be more cost-effective than new builds. Indeed, a significant percentage of the building stock

that will be in use in 2050 has already been built. This puts into context the challenge we are facing. Existing standard solutions for retrofitting can be complicated and less effective due to their interconnections with an existing building’s infrastructure. However, the process is simplified with Onyx’s Solar PV Glass through ease of installation. So much so, that traditional installers, with no previous experience of the Onyx Solar product, will be able to install the solution onto an existing building.

intelligent glass solutions | spring 2022

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

RETROFIT PHOTOVOLTAIC SECOND-SKIN FAÇADE REDUCES ENERGY INTENSITY BY 35%: COCA-COLA/FEMSA bottling plant in Mexico upgrades the existing building to the net-zero economy reducing 11 Tons of CO2 emissions. The installation didn't require stripping from the existing fabric of the building or vacating it. Credits: ©Onyx Solar Energy

1950s BUILDING RENOVATION: The renovation of Freedom building incorporates a PV facade, providing it with additional electrical efficiency and sustainability. Credits: © SALEM MOSTEFAOUI FOR PCA-STREAM

100

intelligent glass solutions | spring 2022

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

RESIDENTIAL BUILDINGS: Photovoltaic façade cladding generates renewable energy while offering the highest rated fire safety (Class A). Credits: ©Onyx Solar Energy

THE LARGEST OF ITS KIND SKYLIGHT IN THE USA & CANADA: Bell Works & Edmonton Convention Centre are great examples of renovation projects that replaced old skylights with photovoltaic glass. They are transparent, allow natural light to come into the building, and future-proof these projects. Credits: ©Onyx Solar Energy

intelligent glass solutions | spring 2022

101

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

Not just the Built Environment From outdoor furniture to self-sustained bus stops, Onyx Solar PV glass has been utilised outside of buildings. Here are some applications transforming several industries: Roof tiles that pay the electricity bills: Our photovoltaic tiles are a breakthrough innovation like no others. It installs just like regular tiles but offers renewable energy generation capabilities. Outdoor Furniture that generates energy from the sun: We developed a pioneering photovoltaic kit that enables outdoor furniture to generate clean, free energy from the sun. The kit consists of a photovoltaic glass module and the electrical materials necessary to connect electronic devices (mobile telephones, laptop computers, tablets, etc.) via a USB port. The table also works in shaded areas using our A-si glass. Furniture manufacturers are already using our kit to build beautiful pieces. It may not be that far in the future that all furniture manufacturers will offer photovoltaic lines, allowing their customers to charge mobiles from the sun. Street Furniture: From bus stops to shelters for public transport, the application of our PV glass is boundless. Generate energy where there is Asphalt: Our Acoustic photovoltaic barrier on road networks can make the vision of green roads possible. Savvy Financial Investment While ROI and payback are critical to all decision-making, sustainable and environmentally friendly solutions to decarbonise a project should not be traded off against improving the bottom-line. The good news is that Onyx Solar glass is not only an investment towards a more sustainable future, but it is also a wise financial investment offering attractive payback periods. Whether it's sunny Spain or not so sunny Canada, implementations in five continents have proven that this building material makes economic sense for our clients.

•

Here are some of the key benefits of using photovoltaic glass:

•

• Future proofing new developments and the safeguarding of existing portfolios against climate change. • Delivering energy goals, reducing emissions

• •

102

and improving resilience by maximising onsite renewable generation. Reduced operational costs. Significantly offset energy demand for indoor air conditioning, reduced HVAC size and usage. PV glass thermal insulation can also reduce up to 45% on energy demand. Offers value for investors and tenants by increasing building sustainability, resulting in lower void periods. Increased rental value by up to 11%. Helps achieve green building certification standards.

intelligent glass solutions | spring 2022

What LEDs have done for energy-efficient lighting; Onyx Solar PV glass has done for sustainable building development. Indeed, cutting-edge glass is greener. People want to go green With the help of my friend Bachu Rajeshwar, a climate activist, CEO, Forbes 30 under 30, and co-founder of several sustainability ventures, we managed to reach out to a large audience and run a survey. The survey asked if participants would like to have standard glazing or photovoltaic glass on the apartments they live in or places they work. 94% of people voted

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

to have photovoltaic glass installed instead of ordinary glazing. In addition, The National Association of Homebuilders survey also noted that the majority of the younger generation of homebuyers wanted built-in environmentally green and sustainable features. Technology will enable change, but leadership will make it happen Technology has transformed the way we design, build and utilise buildings; from 3D printing project models and Virtual Reality to enable better planning, to utilising drones to

survey areas from a bird’s eye view, innovation is pathing the way forward. How can technology help us innovate towards sustainability in the built environment? Existing solutions such as sensors that turn lights on, Artificial Intelligent thermostats that analyse household habits and adjust accordingly, AI software that sends an alarm to smartphones if faucets are left running are all key examples of sustainable best practice. The marginal gains from each of these sustainable solutions, together, contribute to the net-zero aspirations of a project. PV glass has its role to play, tapping the benefits

of existing and future vertical spaces that can contribute to a greener and energy-producing building. Smart buildings with smart systems and onsite energy generation can save resources and money. To deal with climate emergency, the leadership teams in organisations, governments, and businesses will need to adapt and deliver clear strategies that benefit us as a species – whether through policies, setting new agendas, allocating funds, innovating new technologies, the future is in our hands. Amber Gupta, Accredited Professional, Onyx Solar Energy Amber Gupta received his master’s degree in Engineering from the University of Sussex (UK), and has worked in the area of technology ever since. He currently focuses on driving sustainability in the built environment. Amber started his collaboration with Onyx Solar Energy in 2020 and saw what impact innovative technology could have on the construction industry. He advises organisations, architects, developers and leadership teams to make decisions with potential long-term consequences for the planet while achieving their business objectives in real estate development and renovation of existing stock. Email: info@onyxsolar.com Phone: +34 920 21 00 50 Website: www.onyxsolar.com

intelligent glass solutions | spring 2022

103

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

Coming Soon…

IGS Summer 2022

Now more than ever, industry is in need of innovation. The climate crisis, pandemic and rising populations have made us fundamentally rethink the functioning of our cities, public spaces, buildings, and homes. There is widespread belief that the glass industry is traditionally quite conservative and perhaps slow moving compared to others – marred by stagnant innovation and any meaningful breakthroughs, is an association that seems to have been stuck with our industry for years.

104

intelligent glass solutions | spring 2022

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

“Should you find yourself in a chronically leaking boat, energy devoted to changing vessels is likely to be more productive than energy devoted to patching leaks.” - Warren Buffett

In the Summer Edition of 2022, IGS Magazine aims to to break the glass industry free from this perceived bondage of stagnation. Readers will gain foresight into intelligent technology and cuttingedge glass products that are disrupting the status-quo (NOW) and expanding the possibilities of architecture and façade design. From developments in curved glass, bird-safe and fire-resistant glazing to smart glass and digitalisation you will be privy to the innovative spirit of modernist glass industry vanguards. Through project case studies and expert thought leadership, we explore the diversity of design applications, alongside industry developed facade systems and structural glass solutions that set new parameters of possibility for this magical material.

This is IGS – Nothing more, nothing less…NOTHING ELSE intelligent glass solutions | spring 2022

105

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

FLEXIBLE

@ Takuji Shimmura

106

intelligent glass solutions | spring 2022

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

SPACERS: More efficiency in the manufacturing of insulating glass

he warm edge insulating glass is a technically mature product for a highly competitive market that is characterised by low margins, a shortage of skilled workers and cheap imports, and also currently by supply bottlenecks and rising material costs. Christoph Rubel, European Technical Manager at Heinsberg’s Edgetech Europe GmbH, explains which levers the processor and manufacturer of insulating glass has got in order to increase efficiency and product quality in this volatile environment, using the Super Spacer® flexible insulating glass spacer system as an example.

Christoph Rubel

intelligent glass solutions | spring 2022

107

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

The Scandinavian countries pioneered triple glazing and the rest of Europe has followed suit. In Switzerland and Austria, high-quality energy-saving windows have now more or less become the norm and in Germany, according to current information provided by the industry associations, around three quarters of window units in new residential and non-residential buildings are designed with triple glazing. There is a similar proportion of thermally optimised spacers. They prevent the formation of thermal shortcuts at the edges of the insulating glass through which valuable energy is lost. Anyone who decides in favour of a warm edge with a passive house certificate - whether as a processor, architect, builder or building owner - is opting for a mature, future-proof product, and to a large extent no longer has to compare the PSI values at the third digit after the decimal point. All these products make a significant contribution towards low U-values and thus lower heating and cooling costs as well as an improved indoor climate. In addition, condensation and mould formation at the edge of the glass virtually no longer occur. Lever 1: The structure of the edge seal The expression, "the whole is more than the sum of its parts" also applies to the edge seal. The spacer and its desiccant capacity, in combination with primary seal and secondary sealant, are an essential element in ensuring the water vapour and gas impermeability and energy performance of the insulating glass unit throughout its entire product life, which is widely believed to be at least 25 years. The various spacer technologies on the market can be roughly broken down into two categories, which, entail considerable differences where the manufacturing of the insulating glass is concerned: rigid hollow profiles that are filled with desiccant and assembled to form spacer frames, as well as flexible systems that already contain a desiccant. Flexible thermoplastic spacers made of Polyisobutylene are extruded from a barrel onto the glass pane while still hot; spacers made of silicone structural foam come prefabricated from the roll and are also applied automatically along the edge of the glass. Therefore, when using flexible spacers, the production steps of cutting, bending and assembling as well as desiccant filling and separate butyl application outside the insulating glass line are eliminated.

108

Super Spacer® warm edge spacers ensure high levels of manufacturing precision and quality, especially for large-format or triple insulating glass units. With Super Spacer® set in parallel down to the last millimetre, it guarantees a visually appealing and above all tight edge seal. Super Spacer® keeps the panes exactly at a distance and ensure that insulating glass is durable even after decades.

Spacers must be resistant to wind and climate loads, UV radiation, temperature as well as mechanical stress and form a permanent bond with the respective sealants such as Polyurethanes, hot-melt butyl or silicone. Gas must not be allowed to escape from the interior, nor must moisture be allowed to penetrate through the edge seal to the inside of the insulating glass, and last but not least, the edge seal is also responsible for ensuring the structural integrity of glass constructions in the facade. Super Spacer® structural silicone foam design makes the edge seal flexible, cushions the pressure on it so to speak and the risk of breakage for the glass is significantly reduced. Less stress in the edge seal results in an improved seal tightness and durability of the glass units. The full or partial offsetting of the loads acting on the edge seal is an advantage that especially desiccant integrated preformed flexible spacers, such as Edgetech

intelligent glass solutions | spring 2022

Super Spacer® TriSealTM can claim to possess by comparison with rigid spacers. The manufacturer proves the material properties by means of corresponding tests. We at Edgetech/Quanex have, for instance, tested the shear load capacity for the quick handling of the glass units within the factory. An insulating glass unit measuring about 6 x 3 metres wide and 6 mm each thick, was only bonded by means of the integrated primary, high-strength acrylic adhesive. The unit was lifted on one supported glass lite using vacuum cups and the spacer did not give a single millimetre during the 30 minutes test phase. The test demonstrates: The additional adhesive layer reduces the stress on the primary PIB seal, which thus functions exclusively as a water vapour and gas barrier to the secondary seal. In the so-called Dade Country Hurricane Test (an US based test), the units withstood wind speeds of 350 km/h where a positive wind

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

With Super Spacer®, the application process makes sure the spacer is perfectly aligned to create a perfect parallelism. Every corner at the edge seal has a perfect 90 degrees angle, no matter whether it is processed manually or automatically. By cutting straight 90° mitres out of the flexible spacer, corners can be cut very precisely and very accurately into sharp 90° corners.

The structural foam of Super Spacer® is compatible with all quality brand insulating glass sealants such as hot melt butyl, Polyurethanes, 2-part Silicone and Polysulfide. The edge seal is responsible for ensuring the structural integrity of glass constructions in the facade. The elastic silicone structural foam of the Super Spacer® makes the edge seal flexible, cushions the pressure on it so to speak and the risk of breakage for the glass is significantly reduced compared to rigid spacer bars. Less stress in the edge seal results in an improved seal tightness and durability of the glass units.

intelligent glass solutions | spring 2022

109

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

Flexible spacers from the roll are typically applied automatically via a double-head applicator, so the majority of set-up times are eliminated, and the line is flexible to the maximum possible extent in terms of the insulating glass dimensions, glass type, number of panes and spacer colour and widths. The efficiency is enhanced by the easy 3-step process for creating a more fluid production process.

pressure was present and of almost 400 km/h where a suction effect was evident. The test did not end in a unit failure, but was stopped as the test stand was not able to produce higher wind loads. Lever 2: Variability and flexibility A mix of series production and customised production as well as automation and manual activities, for instance for the handling and assembly of panes and spacers, characterises the situation in many European insulating glass companies. The trend towards large panoramic window panes as well as freeform and curved glazing further increases the complexity of the variant production that is typical for the industry. This traditionally 110

meant that a large number of different spacer systems had to be kept in stock: ranging from inexpensive stainless steel profiles to rigid hollow plastic profiles on one side and flexible spacers on the other side, which reveal their benefits especially in the field of automated production. At Edgetech/Quanex we have always embraced a philosophy of "one for all". Super Spacer® flexible foam spacers are suitable for manual application in custom-made products, automatic processing in the edge seal of classic windows with and without internal or externally applied muntin- and glazing bars, insulating glass units in structural glazing facades and also for hot and cold formed curved insulating glass sections. Furthermore, the structural foam

intelligent glass solutions | spring 2022

is compatible with all common sealants such as hot melt butyl, Polyurethanes, silicone and Polysulphide. Last, but not least, insulating glass units with Super Spacer® can be handled, packed and stored outdoors immediately after they have been processed, as the integrated desiccant dries down the interpane cavities very rapidly. The additional price for Super Spacer® is just a few cents per running metre. Therefore, Edgetech recommend that any investment decision should take account of the considerable potential for savings elsewhere. Differences in energy consumption levels brought about by the various spacer technologies are also becoming increasingly important at a time of rising energy prices.

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

Super Spacer® can be applied in various widths (sizes 3 mm to 32 mm insulating glass cavity of which 8 to 28 mm can be applied in automation) via a double-head applicator without interruption. Due to the fact that the flexible Super Spacer® is already factory-equipped with desiccant, barrier film and structural acrylic adhesive, it supports automated processes and ensure high levels of manufacturing precision and quality, especially for large-format triple-glazed insulating glass units.

@ Edgetech

Lever 3: Automation Since the era of Henry Ford, the idea of "economies of scale" has become second nature to us. We reduce our unit costs through greater output. According to this maxim, automation to increase efficiency is only worthwhile for larger production volumes. However, digitisation is now making precisely the opposite possible for the production of insulating glass: We make use of economies of scope. Costs are reduced by optimising the production landscape, processes and infrastructure so that we can use them to manufacture related products all the way down to a batch size of 1. Producing more quickly, more efficiently and in a more customised manner is also becoming a decisive

competitive advantage for SMEs. In the best case, the insulating glass line does not care whether a rectangular pane is followed by a trapezoidal one, or a triple insulating glass unit follows a double insulating glass unit, the ERP system provides all the necessary information and takes care of the digital organisation of the order processing, work preparation, material provision, handling and logistics. This variety is theoretically unlimited and forces us to reduce complexity as far as possible. Broken down in terms of our topic of spacers, flexible spacers also offer the greatest potential here. Fewer machines and the elimination of space-consuming magazines for the provision of the different six-meter-long spacer profiles and the elimination of handling steps reduce the need for machinery, space requirements, storage requirements and personnel requirements compared to the processing of rigid spacers. Flexible spacers are applied directly in the insulating glass line. Super Spacer® can be applied in various widths via a double-head applicator without interruption and, above all, down to the last millimetre and with no hand touching the glass between the start section of the washing machine and the pick off section behind the sealing robot. Due to the fact they are already factory-equipped with desiccant, barrier film and structural acrylic adhesive, they support automated processes and ensure high levels of manufacturing precision and quality, especially for large-format triple-glazed insulating glass units. intelligent glass solutions | spring 2022

111

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

@ Takuji Shimmura

CASE STUDY 1: "ØKERN PORTAL" AND "THE CURVE" SCORE WITH SUSTAINABILITY AND AESTHETICS SUPER SPACER® WARM EDGE IN TWO BREEAM-CERTIFIED PROPERTIES Resource-saving materials are increasingly competing with classic reinforced concrete and facades made of primary aluminium. The energy-efficient Super Spacer® warm edge spacers have been installed in two showcase projects whose main materials could not be more different, but which have an enormous amount in common when it comes to the circular economy. What's more, they exhibit a very unique aesthetic that harmoniously integrates architecture and nature. Since January 2021, all new buildings in the EU have to meet the standard of a "lowest energy building" and should cover their energy needs with renewable energies wherever possible. But energy efficiency is only one side of the coin 112

when it comes to sustainable building. On the other side, the discussion about grey energy as well as the circular use of the raw materials and materials used is gaining more and more momentum. It is not only from politics that sustainable construction is receiving tailwind. Tor-Christian Møglebust, partner in the Oslobased architecture firm DARK Arkitekter, tells us in an interview that the first major tenant of the Økern Portal office complex designed by DARK had explicitly insisted on BREEAM Excellence certification. Økern Portal with facade made of recycled aluminum Økern Portal is one of the largest development projects ever realized in Norway. But it is also

intelligent glass solutions | spring 2022

outstanding because of its striking 14,600 m2 facade made of recycled aluminum. Aluminum producer Hydro's CIRCAL® 75R alloy, made from at least 75 % end-of-life aluminum, has a carbon footprint that is second to none: the guaranteed carbon footprint under 2.3 kg of CO2 per 1 kg of aluminum is 84 % lower than the average for primary extraction and is equivalent to the CO2 released when wood is burned. With WICTEC EL evo from Wicona as the main facade and the Sapa 4150 facade system for the lower two floors, two brands from the Norwegian aluminum specialists are installed in the showcase building. The client and owner is Oslo Pensjonsforsikring. The complex offers 80,000 m2 of space for

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

@ Takuji Shimmura

offices, a hotel, common areas and a food court. Urban gardening, beehives and a running track are planned on the green roofs. Despite the size, the DARK Arkitekter office has managed to breathe lightness into the design. The building stands on stilts to allow for fluid transitions between the public park and the commercial spaces. The aesthetics of the facade, installed by Staticus, establish a connection with the surrounding nature through the arrangement of its 1,588 trapezoidal aluminum elements. Vertically running bands are reminiscent of tree trunks, while the faceting of the horizontal "leaf elements" creates plays of light and shadow and emphasizes the liveliness of the building envelope. The sophisticated system of solar shading, opaque surfaces and double glazing intelligent glass solutions | spring 2022

113

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

@ Roger Holmen

ensures that the facade meets all regulations and energy efficiency requirements.

high deadline pressure," adds Glaseksperten Sales Manager Jess Gregersen.

Insulating glass on demand on the first two floors The first two floors, executed by H-fasader with a Sapa standard facade profile, face in six different directions. Glaseksperten A/S from Hjørring, Denmark, therefore customized the total of 3,000 m2 of triple glazing to meet the different requirements in terms of sound insulation, thermal insulation, safety and space utilization. Among other things, insulating glass with varying sound insulation values between 32 and 39 dB was installed. In addition, invisible sound insulation for walls and ceilings ensures that the retail and commercial areas can be used for a wide range of purposes.

Saint-Denis becomes the secret wood capital of France When, in the 1960s, the A1 highway cut through the historic royal road that led from Paris to Saint-Denis Cathedral, the industrial city in the north of Paris finally became a banlieue. The royal city, which made history as the

"The project was challenging," explains Kent R. Beresford, Sales Manager Norway at Glaseksperten. 12 different glass assemblies were produced in sizes up to 1,200 by 3,000 mm, and the specification for the U-value was 0.6 or less. The outer panes have a highly translucent, color-neutral solar control coating, Sunguard SuperNeutral 70S, while the inside is tempered or laminated glass in various thicknesses. To achieve a thickness of 55 mm for each unit, Super Spacer® T-Spacer™ Premium spacers in widths of 14, 16 or 18 mm were changed accordingly during production in an automated process. "Super Spacer is our preferred warm edge for demanding sustainability projects such as the Økern Portal due to its excellent energy performance. In addition, we always ensure the required precision in spacer application, even under 114

@ Roger Holmen

intelligent glass solutions | spring 2022

cradle of Gothic architecture and the burial place of the French royals, and where the famous Wagon-Lits dining cars were once built, degenerated with the decline of the industrial region into a problem zone with prefabricated housing. But in the shadow of the Stade de France, Saint-Denis is gradually softening the boundaries between the banlieue and Paris. Efforts are being boosted by numerous construction and infrastructure projects for the Olympic Games. Well-known media and service companies have settled here and, according to the city planners, a lively quarter for living and working is being created, which is also developing into a stronghold of French timber construction. For the Olympic Village, which will be built in Saint-Denis by 2024, all buildings under eight stories must be constructed in wood, and taller buildings must at least be designed to be as low-carbon as possible. Thanks to its natural insulating properties, its function as a natural CO2 reservoir and its ease of material recycling, wood from sustainably managed regional forests is an ideal ecological building material. Factory-prefabricated timber frame elements also make timber construction projects increasingly economical compared to classic reinforced concrete construction.

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

Another sign of the new beginning is the 30-hectare eco-district ZAC de la Montjoie in the city center, where particularly strict specifications apply for the promotion of biodiversity and the use of sustainable materials such as wood. In 2020, BNP Paribas Real Estate implemented one of the largest, large-scale European projects in timber construction here with the 7-story office complex. "The Curve", designed by the Chartier Dalix office, houses around 1,600 workplaces, catering facilities and a fitness center on an area of 24,400 m2. The elegantly curved basic form leaves room for 1,400 m2 of open space, and two green areas planted with trees delimit the building from the street. 5,000 m3 of cross-laminated timber elements from Binderholz form the structure; only the building core and the four basement levels are made of low-carbon concrete. BNP Paribas is more committed to sustainability than almost any other real estate developer. "The Curve" is 40% below the energy consumption limits of 50 kWh per square meter on average according to the RT2012 thermal insulation regulations and was designed for HQE Exceptional, Effinergie+ and BREEAM certifications. All bidders were invited to submit proposals for the lowest possible carbon materials.

convexly curved at Döring Glas in Berlin. The asymmetrical pane structure consists of an outer laminated glass with COOL-LITE® XTREME 70/33 coating on the inside, 16 mm Super Spacer® Triseal™ Premium Plus Black as a warm edge, and an 8 mm float glass.

@ Roger Holmen

Plane and curved panes form a visual unit The 10,000 m2 element facade, realized by Metal Yapi, is also part of the sustainable overall concept. In order to flood the offices with as much natural daylight as possible, floor-to-ceiling window areas with windings of between 1,000 and 2,000 mm and a height of 3,285 mm were planned. Saint-Gobain Pietta manufactured the double glazing. In order to find the ideal compromise between comfort, aesthetics and energy efficiency, an extremely transparent and highly selective solar control glass from Saint-Gobain was chosen. The insulating glass units for the rounded building corners were concavely and

"We had ourselves certified according to CEKAL especially for this project in order to underline our high quality standards," says Döring Glas project manager Martin Lenz. He continues, "Despite our vast experience, the panes on the first floor and entrance area were a challenge in terms of manufacturing and logistics. The units are up to 3,000 mm wide and 4,102 mm high, weighing in at just under 900 kg. One unit was also screen-printed with a white pattern to provide a barely perceptible visual screen from the outside to the inside. Another requirement from the customer was to precondition each individual insulating glass unit to increase its service life. For each individual insulating glass unit, the pre-calculated pressure was set individually according to the specifications." Joachim Stoss, Managing Director of Edgetech Europe GmbH and Vice President International Sales at Quanex is proud: "Architecture is currently on an incredibly exciting path. I am confident that together we as an industry will succeed in significantly reducing the carbon footprint of buildings thanks to sustainable materials and consistent circular economy. We are very happy that we at Økern Portal and The Curve were able to make a small contribution again with our warm edge."

@ Roger Holmen

intelligent glass solutions | spring 2022

115

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

CASE STUDY 2: ECOLOGICAL AND ECONOMIC FLAGSHIP PROJECT IN DENMARK SUPER SPACER® INSTALLED IN THE BASECAMP LYNGBY

Affordable architecture is one of the most pressing concerns of our time. However, the issues of sustainability, energy efficiency, land sealing, recycling management, comfort and social integration are contrary to the economic demands. Lars Gitz Architects and BaseCamp Student pulled off the remarkable feat of combining these complex requirements within a spectacular, multi-award-winning student residence. Serial, modular construction, lowcost, recyclable facade materials, renewable energies and near-natural building greenery and seepage areas were the key to success here. One of Scandinavia's leading glass processors, Glaseksperten A/S, has contributed towards the realisation of the ambitious building concept of the BaseCamp Lyngby on several occasions: Automated production of the insulating glass units, varying direction-dependent glass 116

construction and use of the warm edge spacer system Super Spacer® T-Spacer™ Premium Plus. Record-breakingly fast, sustainable and economical The running track on the roof of Google's new European headquarters in London will be used for the first time in 3 to 4 years at the earliest. The residents of BaseCamp Lyngby, built on a 41,000 square metre site, were able to don their running shoes as early as August 2020: a park landscape was created on the green roof of the extensive student residence complex in northern Copenhagen using a system of biodiverse planting, urban gardening areas and an 800-metre-long path that can be used for walking or jogging as you please. From the flat terrain, it winds its way up six storeys above the organically shaped building back down to

intelligent glass solutions | spring 2022

the starting point while enclosing cosy inner courtyards and a circular community centre in the process. The facades are reminiscent of tall trees and forests by virtue of the vertical arrangement of the panels in three different shades of oak wood as well as the line of windows, and in just the same way as the entire complex they blend harmoniously within the surrounding nature. The project developer, BaseCamp Student Nordics, a part of the Europe-wide BaseCamp Group, deliberately wanted to give something back to Lyngby Municipality and enter into dialogue on social and environmental aspects. The roof is therefore open to the public to provide meeting areas. The construction time for a project of this size is impressive. The 786 flats, including 639 student

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

@ Kontraframe

intelligent glass solutions | spring 2022

117

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

flats and 48 senior flats, were completed near Lyngby University of Technology within the space of two and a half years. The building was also intended to be no less spectacular, but one aspect distinguishes BaseCamp Lyngby from many other major projects: Ecology and economy determined the architectural concept equally. Modules as the basis of architectural aesthetics In order to meet the estimated construction costs of around € 75 million the Danish firm of Lars Gitz Architects designed a trapezoidal module that is repeatedly rotated by 180°

118

and stacked at different heights to create the gently rounded structure. The outer skin also constitutes a model example of cost-efficient construction. The ventilated curtain wall is insulated with rock wool and clad with slabs made of pressed volcanic basalt rock from Rockpanel. With a weight of 8.4 kg per m2, the extremely light material can be cut to size on site and simply attached to the substructure. The facades panels with their natural wood look almost entirely consist of natural volcanic rock and recycled rock wool and can be repeatedly reused in line with the idea of a circular economy. This makes the facade one

intelligent glass solutions | spring 2022

of the pillars of the sustainability concept, which has been awarded BREEAM Very Good certificate (equivalent to the DGNB certificate in silver). The energy-saving green roof with the photovoltaic modules serves as a form of thermal insulation, an energy provider and natural air conditioning. The rainwater that is captured is returned to the natural water cycle via evaporation, which consequently relieves the burden on the sewage system and lowers the ambient temperature. Energy-efficient windows with warm edge spacers The aluminium windows with triple glazing

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

also form part of the overall concept. As is so often the case in Scandinavian architecture, the BaseCamp studios and communal areas are glazed down to floor level to allow as much daylight as possible into the room even during the winter. The Danish insulating glass manufacturer Glaseksperten supplied 4,000 insulating glass units packaged in sizes of up 4.011 x 1.127 metres to the construction site in accordance with a meticulous logistics plan. Due to the organic shape of the building, the glass structures change according to the direction. Depending on the heat input and amount of light, solar control glass, thermal insulation glass or clear glass with varying @ Kontraframe

@ Kontraframe

coatings and glass thicknesses were used. Glaseksperten opted for Super Spacer® T-Spacer™ Premium Plus in various widths as the warm edge spacer system. Sales Manager Jesper Hønning declared: "An ever-increasing number of our customers wish to install energy-efficient windows. We consistently use low-emission thermal insulation glass and solar control glass combined with non-metal warm edge spacers in order to avoid thermal bridges and optimise the heat transfer coefficient.” At the company's headquarters in Hjørring, an ultramodern, automated IG line is available for the production of insulating glazing for sizes of up to 3.2 x 6 metres. "Super Spacer is of key importance to Glaseksperten in supplying quality products which also ensure we are a leading company in economical and ecological terms", Hønning went on to say, "the fully automated continuous application of spacer from the reel saves time and money and guarantees top class product quality that is reproducible.” Joachim Stoss, Managing Director of Edgetech Europe GmbH and Vice President International Sales at Quanex added: "Northern Europe is a global pioneer in the field of climate protection and therefore one of the

growth markets for warm edge products. Of course, we are extremely proud that our Super Spacer system has been installed in another Scandinavian flagship project". About Edgetech Europe GmbH, A Part of Something Bigger Edgetech Europe GmbH, located in Heinsberg, Germany, is a fully owned subsidiary of Quanex Building Products Corporation, (NYSE: NX) a global, publicly traded manufacturing company primarily serving OEMs in the fenestration, cabinetry, solar, refrigeration and outdoor products markets. Edgetech Europe GmbH services markets in continental Europe with a total of 490 employees and 17 extruders. We are “A Part of Something Bigger” by improving the performance and aesthetics of end products through continuous innovation, helping customers achieve greater production efficiencies, and giving back to communities where we operate. Visit quanex.com for more information.

intelligent glass solutions | spring 2022

119

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

Decarbonising the Glass Industry and Built Environ

A GLOBAL INDUSTRY IN NE

January 2021, Glass Futures’ container glass biofuel trial at Encirc, (a Vidrala Company) for the Industrial Fuel Switching Phase 3 programme

120

intelligent glass solutions | spring 2022

y nment:

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

he world is in a tumultuous and changing period and it feels like every industry, business, country and individual has a reason to respond more than ever to the world around it. I personally feel that the commonly used phrase of the past two years, “the new normal” is precisely the right terminology for the world to adopt when thinking about the approach to business and sustainability in the 21st century.

EED OF LOCAL SOLUTIONS In reading about the impacts of climate change and shifting geopolitical sands, what is very evident is that the events happening around us apply more pressure to the system and force it to adopt a new footing. Business is focused on providing a stable operation, with predictable returns in known markets. The events of the past two years have caused a seismic shift in “business as usual” and sustainability is being recognised at board level due to its increased prevalence as an over-arching issue that will outlast any pandemic or conflict. It can be difficult to see how such established industries with entrenched processes can also keep up with the rate of change of society but the reality we face is that they must move with the times, lest they cannot serve the society that we are building. In my brief time working across the built environment sector, it is easy to understand how multi-faceted projects, relying on complex supply chains can find it hard to move away from the standard and implement new and changing approaches.

intelligent glass solutions | spring 2022

121

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

In much the same way, industry must take fewer risks for the safety of its businesses, processes and people, the built environment is not inclined to take risks when it comes to designs, specifications and delivery. Ultimately, certainty is our safety net but when looking around, one thing everyone would be happy to acknowledge is that we are far from certain about what our future holds. Whilst it is easy to discuss these items and sometimes feel like entrenched systems are immovable, the last 12 months have shown me that the glass industry is on the move after a prolonged period of stability and certainty; it is not afraid to get ahead of the curve. The rise of Glass Futures is both riding on and helping to shape a wave of change built around a few key ideals that I have heard re-enforced across industry, which are critical to the way we approach the new normal: • Some challenges are too big for individual organisations, and we must collaborate to move forward. • We do not know what the future looks like, but we know we must think differently. The real challenge for the industry The world needs change and the method for manufacturing glazing is very similar throughout

122

the entire world so any single solution could be rolled out across the world with relative ease, in theory. The big issue is that there are several different key aspects that determine each manufacturing sites’ decision-making process: • • • • •

Local laws and environmental policies Energy prices for operational energy Costs for energy infrastructure The age of the installation Design and capex philosophy of the company • Size and space constraints on site • Domestic and international competition As seen from the above list, the truth is most of the impacts that determine a plant's approach to sustainability will be largely driven by geographically dependant aspects. All the above feed into a complex list of decision making processes which ultimately come down to cost, profitability and the balance of strategy. Consumers vote with their money, and in the glass world, consumer facing brands are leading the way when it comes to sustainability because the consumers of the world are bringing the sustainability question to bear. Within the construction sector, a “sustainable” approach is almost still reserved for the public sector and wealthy clients who can afford to

intelligent glass solutions | spring 2022

Image taken by UKRI: CEO UKRI speaks to Richard Katz, Chief Executive of Glass Futures & Aston Fuller – General Manager of Glass Futures while visiting the UKRI stand in the Green Zone at United Nation’s COP26, Glasgow UK on 09 November 2021.

invest in the “extras” that are associated with sustainability. The reality is that the world is committed both legally and morally to decarbonising but we do not know how to do this in a way that is economically sustainable yet. Companies the world over have equally made commitments but these targets and commitments require

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

The United Nation’s COP26 summit Like many others who applied to exhibit at COP26, we hoped to present at this exhibition to showcase challenge and demonstrate the action we are taking to lower carbon emissions. 15–20 permanent exhibits were successfully selected from thousands of applications, Glass Futures being one of them. I believe our selection was a recognition of the urgent need to collaborate effectively to achieve carbon goals being set. In my opinion, our project exemplifies what a highly positive collaboration can actually achieve, not just as a long-term target but demonstrable in the here and now. We successfully conveyed a message of

collaboration and that this is an industry that can work together with the public and private sectors. We did this by working together with organisations to help share their own messages and what they are doing to support sustainability. This was sponsored by one of our major corporate members and they openly provided the opportunity for competitors in the industry to share the same platform. This kind of action helps extend the olive branch and lets organisations know that through the ideal of mutual benefit, we can achieve momentous results, together. This message is precisely the underpinning sentiment of COP26 and I am glad that we embodied the message on the world stage. Glass Futures at United Nation's COP26 summit in the Green Zone, Glasgow UK, exhibiting revolutionary trial as part of the Industrial Fuel Switching Phase 3 Programme

support, investment and hard work to be achieved. I, myself and several colleagues saw just how far reaching this commitment goes at COP 26 last year and it invigorated me to see that from the biggest to the smallest countries around the world, every industry is looking at ways to transform and become the thought leader.

Exhibition by UK Research and Innovation (UKRI), Diageo, Glass Futures and the global glass industry at the United Nation's COP26 summit in the Green Zone, Glasgow UK

intelligent glass solutions | spring 2022

123

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

Economics of green combustion I am proud that recently Glass Futures has been breaking the mould in its approach to changing the industry, as such, we are almost continuously running trials into low carbon alternative fuels for glass furnaces as part of Glass Futures’ Government contracted Industrial Fuel Switching Phase 3 programme. Given that combustion is the key energy source for most global glass manufacturing, if we can move away from natural gas, we can decarbonise the manufacturing process at the source. The reality here however is that large furnaces melting upwards of 800 tonnes per day are highly risk averse and the need to de-risk these activities is essential before anything at a meaningful scale can be done.

In January 2020, Glass Futures was awarded a £7.1m contract by The Department of Business, Energy and Industrial Strategy’s (BEIS) Energy Innovation Programme. This work involves test firing hydrogen and biofuels in a scale model glass furnace at temperatures in excess of 1500 °C, simulating real world firing conditions for alternative fuels to lay the foundation for full scale trials. The project is also evaluating the associated technical, economic, and environmental aspects of fuels and encompasses a wide range of industrial and academic partners; the final report for this work is due to be published by BEIS in summer 2022. It is very clear from the work that is publicly available that the success of the programme

The 350kW combustion test bed for the Industrial Fuel Switching Phase 3 programme

First flame’ for the Industrial Fuel Switching Phase 3 programme, image taken inside the 350kW combustion test bed

January 2021, Glass Futures’ container glass biofuel trial at Encirc, (a Vidrala Company) for the Industrial Fuel Switching Phase 3 programme

124

intelligent glass solutions | spring 2022

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

has been outstanding and it is due in large part to the collaboration and co-operation of the whole glass industry, not just within the UK, where we carried out our trials, but also across the global business owners based across North America and the EU. The UK Government released its Net-Zero strategy ahead of COP26 , which sets out how the UK will deliver on its commitment to reach net-zero emissions by 2050, outlining measures for the transition to a green and sustainable future. The strategy announces an extra £500 million towards innovation projects, bringing the total funding for net-zero research and innovation to at least £1.5 billion to support technologies that decarbonise glass and other

industries. This amount of funding is simply the UK commitment! Horizon 2021 funding in the EU, Department of Energy in the US and many other global institutions are spending a significant amount of money investigating this question and it is understandable, looking at the rate of change needed and the technical questions that need to be answered in the meantime. Encirc and the “world’s most sustainable bottle” In January 2021, as part of this revolutionary project, glass container manufacturer, Encirc (a Vidrala company) and Glass Futures demonstrated that new bottles can be made from 100% recycled glass, using only January 2021, Glass Futures’ container glass biofuel trial at Encirc, (a Vidrala Company) for the Industrial Fuel Switching Phase 3 programme

intelligent glass solutions | spring 2022

125

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

January 2021, Glass Futures’ container glass biofuel trial at Encirc, (a Vidrala Company) for the Industrial Fuel Switching Phase 3 programme

the energy from burning ultra-low-carbon biofuels, achieving a 90% reduction in carbon footprint, I was personally on-site during these trials and seeing something achieved in a real world manufacturing environment was truly energising. Made from waste organic materials, biofuels are a renewable and sustainable fuel source when compared with those traditionally used by the glass sector and can reduce the carbon footprint of each tonne of glass by up to 90%. By using up to 100% recycled glass to create the new bottles, the trial was able to even further minimise the lifetime impact of these products. As part of this trial, millions of containers were manufactured for a number of wellknown global drinks organisations including Diageo and Heineken, putting real, low carbon products into the hands of consumers throughout 2021 well ahead of any global net zero targets. This trial ran for three weeks on a full-scale furnace and allowed us to de-risk the planned trial for a float glass furnace which was the next step following a successful demonstration. 126

NSG and the “World’s lowest carbon float glass” In February of this year, Glass Futures supported Pilkington United Kingdom Limited (part of the NSG Group) to manufacture the world’s first flat glass produced by a furnace fired on 100% biofuel as part of one of the key final deliverables for our Industrial Fuel Switching project. We ran the trial successfully for four days, creating 165,000 sq ft of the lowest carbon float glass ever made. The embodied carbon within this glass contains circa 70% less CO2 than traditional float glass made and one of the home truths which we faced in talking to the wider market about the opportunities is that no one is asking for low carbon glazing at the moment, because customers have never been offered such a product before. I believe generally most people have thought that low carbon products are a thing of 2030 or 2035 but it has been empowering to see we have proved we can do this now if the market demanded it. The truth as it currently sits is that while all these things are possible, they come with an economic cost without doubt, this means we will see low carbon products being seen as a premium

intelligent glass solutions | spring 2022

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

option in the short term, before becoming more mainstream. Global Industry It is sometimes easy to miss that with such a large global commodity market that we still tend to move towards domestic manufacturing, and while the rise of global shipping has sometimes seen domestic manufacturing move abroad, this trend struggles when dealing with very heavy, relatively low cost materials, of which glass (in its pure form, without coatings) certainly is. This is driven by the high energy requirement and use of sand, limestone, soda ash and cullet which are all products that you want to pay as little for transport as possible. And the same will go for our low energy sources of the future, we will rely on keeping costs down including reducing manufacturing costs. We have seen

January 2021, Glass Futures’ container glass biofuel trial at Encirc, (a Vidrala Company) for the Industrial Fuel Switching Phase 3 programme

February 2022, Glass Futures flat glass biofuel trial at Pilkington United Kingdom Limited, (part of the NSG Group) for the Industrial Fuel Switching Phase 3 programme

intelligent glass solutions | spring 2022

127

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

from our research that geography is going to play such a big part in the future energy use of all industries, driven by local, regional and international policies around hydrogen, biomass, electricity and of course, natural gas. A Problem Shared The issues discussed are not only a glass industry issue, and moreover within the whole built environment everyone is facing the same challenges but at different times and levels of growth. As such we have realised that working across materials is vitally important, in particular within other Foundation Industries that serve civilisation and the built environment. There are parallels seen in brick making, steel manufacturing, chemicals and plastics, and cement. Everyone has to make huge changes sooner rather than later and we must look across innovations of old and new within all of these sectors to ensure we progress as quickly as possible; this is where the entire supply chain becomes vitally important. For all architects, specifiers, public policy makers, quantity surveyors this is where you can help play a role by driving the conversation and the request to ensure that our materials, from the beginning of the supply chain are made in a sustainable way. The Big Problem The decisions we must make as an industry rely on long term confidence and ultimately there is a huge amount of uncertainty in the world around us, but there is no choice in the end, so we are left with a few key questions:

128

How does the industry change its model to keep pace with the change of society? How can we enable the industry to make bold decisions in the face of uncertainty for regional energy availability and prices? What technology developments need to be carried out and what can we do to increase economic certainty in energy prices? To Collaborate Is To Create If we do not work together and help create an industry working to change its manufacturing processes, the industry will stifle innovation in deep decarbonisation. I believe that if we do work together, we can accelerate innovation and increase visibility for sustainability projects. This is exactly the reason I am deeply and personally attached to the work of Glass Futures. We are a not-forprofit research group with a mission to help bring about low carbon glass sooner rather than later. Much of the answer is rooted in connecting across the entire value chain, and we welcome all who want to be involved in this global shift. There is a huge amount of passion across this sector to see this change happen but the answers we need are a combination of processes, cost and people and the space we occupy as a facilitator, introducer and thought provoker allows us to work with our members to promote a new approach to problem solving, so people can find unique solutions for themselves or their clients.

intelligent glass solutions | spring 2022

Aston Fuller, General Manager at Glass Futures Aston is the General Manager of Glass Futures. He is responsible for the day-to-day running of Glass Futures and to ensure that the activities carried out across the Glass Futures programmes align with industry trends, technology and direction. Aston has worked in the glass industry for over 10 years. He spent 8 years with Ardagh Glass, gaining experience in furnace management, operation, maintenance and capital construction, wider plant engineering and energy management before working with British Glass and GTS on wider cullet recycling research projects, prior to joining Glass Futures. With a keen interest in entrepreneurship and innovation, especially in relation to sustainability, Aston has over the past few years developed a passion for driving change in sustainable engineering, manufacturing and in helping open knowledge of the glass industry to a younger generation of engineers.

2050 FLAT GLASS IN

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

CLIMATE-NEUTRAL EUROPE TRIGGERING A VIRTUOUS

CYCLE

OF DECARBONISATION

The European ﬂat glass sector takes it as its role to produce at a competitive price the materials essential for renovating Europe’s buildings, for supporting the clean mobility transition and for increasing the share of renewable solar energy in Europe. Discover more: www.glassforeurope.com intelligent glass solutions | spring 2022

129

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

The Future of Glass Melting Reducing Carbon Emissions Ir. H.P.H Erik Muijsenberg; Glass Service, a.s.

130

intelligent glass solutions | spring 2022

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

intelligent glass solutions | spring 2022

131

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

Sustainable glass recycling (UN Goal 11) Glass plays an important role in our society. Its usage in housing, transportation, communication, food storage, etc. is crucial to enjoying a high quality of life. To produce glass, we need raw materials and energy. We can reduce the need for materials by recycling more. Indeed, a significant advantage of glass is that it can be endlessly recycled without loss in quality or purity although glass waste needs to be purified, cleaned, and color separated before use. Using more cullet for melting means not only considerable savings in raw materials costs and energy usage, but CO2 emissions are also lower. Clean cullet needs to be reheated and homogenized; but melting reaction energy is not required and every 10% cullet addition reduces the energy consumption of glass melting by 2-3%. To melt soda lime glass from raw materials requires energy of about 2.6 MJ/ kg. As pure cullet, this is reduced to 1.9 MJ/ kg. More importantly, re-melting cullet avoids CO2 emissions from soda ash (Na2CO3) and lime (CaCO3) in the batch. Every metric ton of waste glass recycling saves about 315 kg of CO2 that would be released manufacturing a new glass product [3]. The most common, efficient, end-fired, container glass furnaces, melting with an average of 50% cullet, consume about 3.5 MJ/kg. Sustainable responsible glass production & climate action (UN Goal 12&13) Melting glass requires considerable energy to reach the necessary high temperatures (>1500°C). Glass production used to take place in “glass houses” where people had local resources - sand and wood ash as raw materials and wood from the forest for energy. Old glass houses can still be found in forested areas. As much as 150-200 kg of wood was needed then to melt a kg of glass [4]. Assuming wood burning generates about 19 MJ/kg, this equates to >2850 MJ for a kg of glass. Today’s result of 3.5 MJ/kg is astonishingly 800 times more efficient. Over the last century, the main energy source has shifted to fossil fuels such as oil and natural gas. Modern glass melting uses about 1% of all industrial energy [5] much less than for example steel production. Nevertheless, it is energy intensive and massive improvements 132

Figure 1. Energy efficiency gains over 150 years and NOx, SOx and dust emissions for the last quarter century. (Source http://www.agc-glass.eu/sustainability/environmentalachievements/air

intelligent glass solutions | spring 2022

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

have been made over the years. Asahi Glass Company have plotted these downward trends, and the reduction in pollutants such as NOx, SOx and dust emissions for flat glass production (Fig. 1). Figure 1 also shows that since 2000 the relative specific energy line has flattened, suggesting little improvement in recent furnace designs for flat glass. Furnace efficiency had increased because new refractories allowed higher combustion and crown temperatures, and increased melting temperatures. Furnaces

became larger, producing more glass per m2 of heat loss surface. Some flat glass furnaces now produce a remarkable 1200-1500 tons/ day while container glass furnaces can melt a high 800 tons/day. But furnace size is limited by the maximum crown span (width), the size of equipment, flame length, and other factors. Larger regenerators have increased heat regeneration from 50% to 70%, close to the theoretical maximum of 75%. This maximum arises from the difference in heat flow in the waste gas (greater mass and specific heat) than the air being preheated.

Figure 2. A 350 TPD container glass melter. Courtesy of Glass Service a.s. (www.gsl.cz)

Figure 2 shows the design of the most common U flame (end-fired) container glass melting furnace, producing about 350-380 TPD (tonnes/day). Cold air enters the base of the regenerator at the right and is preheated to 1200-1300°C, before leaving at the top and entering the combustion chamber. Gas (or oil) is injected into the hot air at the base of the port. This example has four injectors. The iso-temperature surfaces indicate the flame shape that develops. The hot gases radiate heat to the glass melt surface, the furnace walls and the crown, the latter two re-radiating energy to the glass. The waste gases then circulate round the furnace and exit via the left exhaust port, entering the opposite regenerator, and preheating it until the process is reversed after 20-30 minutes. Raw materials enter into the melting basin from two sides. First the batch under the flames is melted. Some designs have a barrier wall (0.8 m high) on the bottom of the furnace to bring the glass from a typical depth of about 1.3 m to the melt surface to aid the removal of small bubbles, the so-called fining process. The glass then dives down into the sunken throat to be delivered into the distributor which connects to the forehearth which takes the glass to the forming machines. The small rods protruding from the bottom of the glass basin are molybdenum electrodes that assist in melting the glass by electrical Joule heating, often called electric boosting. Such a melter is typically about 15 m long by 6 m wide.

Figure 3. A cross-fired regenerative 600 TPD float glass melting furnace. Courtesy of Glass Service a.s. (www.gsl.cz)

intelligent glass solutions | spring 2022

133

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

The second most common glass melter is the cross-fired regenerative float glass furnace. Flat glass is formed after leaving the melter by floating the melt on a molten tin bath. This glass is mainly used for window glass or automotive windshields also solar panels or sometimes LCD products can be produced. The furnaces can be 35-40 m long and 10-12 m wide. The most typical pull rate is 600-800 TPD, but some furnaces produce 1200 or even 1500 TPD. These cross-fired regenerative furnaces alternate firing from opposite sides. They have five to nine burner ports on each side and the preheated air comes from brick regenerators on each side. Injectors introduce gas into preheated air to create flames crossing the glass melt surface, the hot waste gases exiting to the opposite regenerators. This process is reversed about every 30 minutes.

Figure 3 shows a 600 TPD float furnace with 5 ports with 2 gas injectors on each side. Raw materials are introduced by batch chargers. After melting, the glass is cooled in the working end and leaves by the canal onto the molten tin, where it spreads out to form a flat sheet. Other furnace designs Other technologies include the recuperative and the oxy-gas furnace. Oxy-gas furnaces use pure oxygen, extracted from air and may seem more energy efficient than the best regenerative furnaces. A correct analysis though requires the energy and cost of separating the oxygen be considered and usually favors a regenerative furnace. However, oxy-gas furnaces can bring other benefits - NOx reductions and a smaller footprint. Recently, two industrial gas suppliers have reduced

energy consumption by preheating the fuel and oxygen. Linde (Praxair) developed the OptiMeltTM technology to save another 20% of energy by preheating the natural gas with waste gas from the oxymelter to create a syngas (CO + H2) formed by cracking CH4 with CO2 in the waste gas [6]. An interesting side benefit is that CO tends to reduce foam on the glass surface, increasing heat transfer and lowering seed counts. Air Liquide designed HeatOx technology with heat exchanging recuperators using furnace waste heat to preheat the natural gas and oxygen indirectly to 400-500°C, giving 9-10% additional energy savings. [7-9]. Should this technology be installed in a conventional Figure 4. A 80 TPD cold top rectangular all electric melter using top, side and bottom molybdenum electrodes. Courtesy of IWG Wagenbauer and Glass Service

134

intelligent glass solutions | spring 2022

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

regenerative float furnace converted to oxy-gas firing, a total of 20-25% energy savings may be achieved. A side effect would be a major NOx reduction. Finally an oxy-gas furnace is apparently converted to burn hydrogen more easily than an air-fired furnace. Burning hydrogen with air gives higher flame temperatures typically equating to higher NOx emissions. Oxy-gas furnaces may therefore be more attractive when hydrogen is affordable. Electric melting The first continuous regenerative glass melting furnace was invented by Charles William Siemens of Westminster England between 1872 and 1880 and modern regenerative furnaces have changed little since. Many do not realize though that continuous all electric melting (AEM) is almost as old as gas-fired regenerative melting. The first electric furnace was built in 1905 following French Sauvageon's design and was for window production. The specific energy consumption was even then only 0.73 kWh/kg. Many designs have been implemented since but recently electric melting has fallen in popularity due to its high cost compared to widely available fossil fuels. Global warming and pressure on carbon footprints, has rekindled interest in full or partial (hybrid) electric melting. Alternative energy sources for electricity have helped to lower costs and production is essentially CO2 free; for example in Germany, 40% of electricity is generated using renewable resources such as wind, solar, hydro, and bio. The question for the future is not if more electricity will be used for glass melting but what will be the balance between fully electric and hybrid furnaces (substituting bio fuel for fossil fuel). Glass is important in generating green renewable energy, or “green electricity.” Most wind turbine blades are composed of reinforced glass fiber. And most solar panels use large quantities of flat glass. In the future photovoltaics will probably be widely integrated into windows. These applications mean that glass is not only a consumer of renewable energy but also has an important role in generating it. For larger furnaces with higher pull rates, the higher volumes and lower wall losses make

recuperators or regenerators sensible. Gas-fired furnaces can be cheaper than the efficient electric melter. This was historically so in most countries because electricity was generated from fossil fuels, and typically 2.5 to 3x more costly per kWh than the fuel alone. Even small electric furnaces are 70-85% thermally efficient. While a fuel fired furnace without a recuperator at a low pull is only 10% efficient, adding a regenerator improves efficiency to 45% and an oxy-gas fired furnace, can achieve 50% efficiency. Most common all-electric melters produced 10-30 TPD, sometimes up to 80 TPD. They were round or hexagonal to avoid heat losses via the furnace walls and to allow more easily distributed batch charging and electric connections. Figure 4 shows a larger rectangular melter at 80 TPD. These cold top electric melters used the batch cover as a heat insulating blanket, conserving heat inside the melt. They were called vertical melters, as the glass melts on the surface near the batch, refines at lower levels and flows out via a bottom throat into a working end/distributor. To maintain batch coverage and hence an insulating blanket, the cullet content was usually below 50%. Electric melters were mostly used for high quality clear glasses and crystal (lead) glasses, as the redox (color) control is best managed with this process. During the 1970 global oil crisis, some glass producers, especially in the United States converted their regenerative furnaces to all electric melters. They retained the infrastructure and horizontal configuration because other shapes were difficult to incorporate into their existing space; sidewall losses are less important at higher pull rates. The future of carbon free melting – electric, hydrogen or hybrid? Currently, 95% of all glass melting uses fossil fuels, mostly natural gas or heavy oil; but industries are now strongly encouraged to follow the Paris Climate Agreement guidelines and are seeking to minimize CO2 emissions. Many but not all countries are enforcing rules, with penalties for carbon emissions and benefits for reductions. Either way, the glass industry knows its consumers expect low-carbon or carbon-free production, so are working to achieve this while remaining competitive amongst themselves and with other packaging materials.

Four key technologies for carbon reduction exist, in addition to those already discussed. They are: 1. Cold top all electric vertical melting (AEM) 2. Hydrogen combustion (replacing natural gas in regenerative or oxy-gas furnaces) 3. Horizontal hot top electric melting (H2EM) also referred to as hybrid melting 4. Horizontal hot top hydrogen electric melting (H3EM) The question is: What is the best solution - not just now - but for 2030? 2050? After 2050? Hydrogen Currently, truly green hydrogen produced by electrolysis using renewable electric energy is the first choice, but there is simply insufficient available. Even with low electric pricing, hydrogen at 6€/kg is three times too costly to compete with natural gas. So, in most regions it would be uneconomic, without state subsidy. More research on hydrogen combustion is needed, specifically the effect on the molten glass and refractories of water concentrations approaching 100% in the combustion atmosphere. Certainly concentrations near 50% in the combustion atmosphere of oxy-gas furnaces created problems. Using electricity to break water into H2 and O2 by electrolysis is expensive and is only now reaching 70% efficiency levels. However, expectations are that investment costs should decline while efficiency continues to increase so that, as more renewable electricity becomes available, hydrogen will become affordable. But why consider hydrogen? If electricity is used directly, the furnace melting efficiency is much higher than via the hydrogen route. An advantage of hydrogen is the possibility of storage for long periods, allowing long-distance transportation and creation of a buffer against supply hiccoughs. Storing electricity for similar times is simply not efficient. Unused batteries slowly lose power while storing sufficient energy would require huge batteries. Different storage options are shown in Figure 5; some, such as hydro power have been created but are not universally applicable, mountains and water reservoirs, as in Norway or Austria being necessary. Energy storage today is facilitated by methane which can be stored for millennia in caves with appropriate geology [10].

intelligent glass solutions | spring 2022

135

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

Figure 5. Showing the capacity and discharge times for different storage technologies. Source RMIT

FlammaTec (part of GS Group) developed THE first Hydrogen burner for glass melting in 2018. https://www.flammatec.com/servicesproducts/burners/gaseous-fuels/hydrogencarbon-free/ All-Electric Melting Electric melting has been a proven technology for over a century so why not convert all furnaces to all-electric melting? Mainly because electricity typically costs three times that for natural gas /kWh. While electric melters are twice as thermally efficiency, they are more expensive to operate. Another obstacle remains. Most electric melters are producing less than 80 TPD. Only a handful in the entire world melt more than 100 TPD; and only two have produced 200 TPD - both were stopped due to production issues. All-electric melters greater than 200 TPD, have diameters so large that maintaining a well distributed insulating batch blanket across the melt surface is difficult although a key requirement for keeping the furnace operational. Should the batch cover disappear, the furnace loses heat from the top, the glass cools, melt quality and pull rate fall and production deteriorates. There is also limited long-term experience at that size of producing reduced colored glasses or melting with high cullet levels.

136

Hybrid melting Hybrid melting entered the glass dictionary in 2017 being mentioned by companies such as Glass Service, FIC, BDF Industries, Fives, Teco, Horn and Sorg. Previously discussion was limited, though hybrid melting simply means more than one heat source and has a long history. It is analogous to hybrid cars where the engine is the main power source, while the battery-driven electric motors can move the car short distances and add extra power during acceleration. Previously, electric boosting in glass production was often for 15-30% of the total energy input. Combustion is also used in hybrid melters (H2EM) but 50% or more energy comes from electric heating. The thermal efficiency of the electricity is 85-90%, while combustion is about 50%. A smaller all-electric furnace (<4 TPD/m2) has the following advantages: • No emissions (NOx, SOx) or particulate dust, so no filter or cleaning costs for waste gas • No chimney stack and therefore fewer complaints from neighbors • Lower investment: no crown, regenerator or flue gas channels • No regenerators to clean • Lower raw materials costs, because volatilization reduced • Lower repair costs and shorter repair times

intelligent glass solutions | spring 2022

• Efficiency is less impacted by furnace size and capacity Common disadvantages are: • Less pull rate flexibility • Shorter furnace lifetime (8 years for smaller furnaces 50-80 TPD) • Limited experience of operators • Dependent on electrical power stability) • Proven melting only up to 55% cullet • Limited experience with producing reduced colored container glass (hybrid melting helps) Hybrid melting removes most of the disadvantages. Glass Service and FIC in cooperation with BDF Industries developed THE first Hybrid design in 2017. A flexible design independent of energy source, melting at times with 80% fossil fuel/ H2 and 20% electric boost (at 3 MJ/kg), or conversely 80% boost and 20% combustion (at 2.5 MJ/kg). This should reduce the risks of adopting a new technology. Figure 6 shows the concept design of such a horizontal hybrid electric melter for container glass. Hybrid electric melting and oxy-gas furnace such as this can break the magic energy barrier undercutting a specific energy consumption of 3 GJ/ton of glass (with 70-80% cullet).

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

Fig. 6. shows 3D view of the combustion space and glass melt in a Horizontal Hybrid Electric Melter at 80% electric mode and 20% firing mode. Courtesy of Glass Service a.s. (www.gsl.cz)

Table 1 shows that using electric energy directly in the glass melt is much more efficient than hydrogen whether by combustion or via the fuel cell. Direct efficiency is estimated to be 79%, whereas hydrogen reduces efficiency below 30%. Also for producing Float glass it will be possible to use much more electric heating or super boosting then was common till now. A design

made by FIC UK to make some first steps into this direction is shown in figure 7 with a 6 MW bottom melter boosting installed in a conventional regenerative float furnace. To make the complete transition it maybe more interesting to combine this also with oxy combustion and then at some point replace the natural gas to more Hydrogen and waste heat recovery. But the efficiency route using Electricity directly will be always higher.

Conclusions and outlook With the help of Industry 4.0 automation & renewable energy sources, the required 55% reduction of carbon emissions should be possible before 2030 through: • improved glass recycling (in both amount and quality) • improved Model Based Predictive Furnace control (Dynamic balancing of Electric vs Combustion firing)

Table 1. Comparison of electric melting efficiency versus hydrogen route intelligent glass solutions | spring 2022

137

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

Figure 7. Float furnace with 6 MW Super boosting, going Hybrid.

• greater use of low-cost green electricity, in hybrid or all electric furnaces • the use hydrogen for combustion or electricity generation Generating hydrogen using green electricity will become important post-2030. The 2050 goal of an 80% CO2 reduction, will require large amounts of green electricity and a functioning hydrogen economy to replace fossil fuels for glass production, and transportation to and from the factory.

in-times-of-scarcity-and-abundance-19391978/ D4119AC7A38C4D29486557CCACF3D4FC

Industry 4.0 automation will continue its forward progression. A dark glass factory may be difficult to imagine by 2030, but not by 2050 when the light from hot gobs falling from the forehearth spout will be all that illuminates the factory hall.

[8]https://www.lifecleanox.com/sites/cleanox/ files/2018/05/30/extractpage_glass_worlwide_mayjune_2018.pdf

References [1] https://www.cambridge.org/core/journals/ contemporary-european-history/article/glassrecycling-container-in-the-netherlands-symbol-

138

[2] https://www.gpi.org/a-circular-future-for-glass [3] https://publications.jrc.ec.europa.eu/repository/ handle/JRC68281 [4] https://en.wikipedia.org/wiki/Forest_glass [5] https://www.eia.gov/todayinenergy/detail. php?id=12631 [6] https://www.lifeoptimelt.com/ [7]https://www.oxyfuel-heatrecovery.com/sites/ oxyfuel_heatrecovery/files/2017/03/28/oxygennatural_gas-preheating-for-oxy-float-glass-air-liquide. pdf

[9] https://www.ecoheatox.com/ [10] https://patents.google.com/patent/US230668A/ en [11] https://patentimages.storage.googleapis. com/99/83/53/27b1751a9d6aed/US972779.pdf [12] https://www.neuman-esser.de//en/company/ media/blog/hydrogen-storage-in-salt-caverns/ https://insideevs.com/news/493578/volkswagen300-gigawatt-betteries-achieve-ev-goal/

intelligent glass solutions | spring 2022

Ir. H.P.H. Erik Muijsenberg GLASS SERVICE, a.s. Erik Muijsenberg is a Mechanical Engineering graduate of the University of Eindhoven from the Class of 1990. For the eight years following graduation, he was employed by TNO Glass group in Eindhoven focusing his efforts in furnace modeling and glass melt technology. In 1997 he became the Glass Department leader. In 1998 he became a GLASS SERVICE B.V. Managing Director, first GLASS SERVICE subsidiary office in Maastricht, the Netherlands. After eleven years he moved to GLASS SERVICE headquarters in Czech Republic to become group Vice President. GLASS SERVICE employs over 100 engineers with offices worldwide including Czechia, Slovakia, Netherlands, Germany, UK, France, USA, China and Japan. In 1997 he was awarded, together with his former colleagues, with the Otto Schott Award. In 2012 he received the Adolf Dietzel Industry Award from the German Glass Society for his contribution to the development and acceptance of glass furnace modeling & optimization in the German glass industry. He was chosen as a Fellow member by the British Glass Society in 2014. Erik is also active Vice Chairman and past Chairman of the Technical Committee 21 – Furnace Design & Operations – of the International Commission on Glass (ICG). As of 2016 Erik became an ICG Steering Committee member. In 2017 he became a Phoenix Award Committee member. Erik has been selected to become the next Vice Chair and future Chair of the Phoenix Award Committee. Erik has actively promoted Industry 4.0 smarter model based furnace and forehearth control and CO2 emission reductions to the Glass Industry for over twenty years.

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION XXXX

SWISSPANEL SOLAR The bespoke printed front glass for solar modules

www.glastroesch.com

intelligent glass solutions | spring 2022

139

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

140

intelligent glass solutions | spring 2022

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

We can’t afford to just build greener We must build less Johannes Novy, Senior Lecturer in Urban Planning, School of Architecture and Cities, University of Westminster

intelligent glass solutions | spring 2022

141

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

s the built environment took centre stage1 at COP26 in November 2021, the scale and urgency of the climate crisis and of the industry’s responsibility to address it comes into focus. A recent report2 from the UN’s Global Alliance for Buildings and Construction shows that the buildings and construction sector is responsible for 38% of global CO2 emissions.

The demolition and new-build construction cycle is a major source of waste. Image by Jarrett Mills on unsplash

Increasing attention has been paid, in recent years, to emissions resulting from how our buildings are operated: how they are heated, cooled and lit. Those due to the production and supply of building materials and the construction itself have received less attention. And yet, they alone account for 10% of global emissions. Much of the sector thrives on a wasteful cycle of demolition and new builds. In the UK alone, an estimated 50,000 buildings are torn down each year. Which begs the question: is building greener really the solution? Whole-life carbon approach Despite efforts by the likes of sustainable architecture pioneer William McDonough4 and organisations including World Green Building Council5, breaking this demolition and new-build cycle has proven difficult. Reusing existing building stock is a complex issue. If not done sustainably, it can also cause a hike in emissions. But there are several other reasons why reuse has not become more of a default option. Many architects have found that it was easier to make a name for themselves with glitzy new buildings than with sustainable design methods and retrofits, and, frequently, more - and quicker – money could be made by tearing down existing buildings and replacing them. Perverse financial incentives play a role alongside other factors: in the UK, for example, VAT rates6 still encourage new builds and penalise renovations. Further there are economic incentives for those who profit from the current system – who sell construction materials, carry out demolitions or whose business model exclusively focuses on new builds, instead of reckoning with existing buildings, refurbishing them and integrating them into new schemes – to not do things differently. 142

intelligent glass solutions | spring 2022

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

Lastly, in architecture education and professional accreditation, as elsewhere, there has been a lack of climate literacy7. This has left architects ill-prepared8 to effectively tackle the climate crisis. Recent initiatives show that things are changing. Architects Climate Action Network9 and Architects Declare10 launched in 2019, are just two of several alliances that aim to raise awareness within the construction industry of the climate crisis, decarbonise the sector11 and drive the shift towards renewable and green building. In addition, Architects’ Journal started the RetroFirst12 campaign in 2019, which advocates for prioritising retrofitting over demolition and new construction. As the latter campaign puts it, the greenest buildings are those that already exist. In September, a report13 published by the Royal Academy of Engineering drew further attention to the environmental costs that the industry incurs and possible ways to address them. Central to this new way of thinking about construction is what architects and developers call a whole-life carbon approach14. Building greener The whole-life approach considers a building’s entire life cycle15, from construction, occupation and renovation to repair, demolition and disposal. In a typical UK housing block, emissions attributable to construction and maintenance account for 51%16 of the building’s total carbon emissions.

Making heating and lighting energy efficient has long been a priority. Image by Johny Goerend on Unsplash

Making buildings energy efficient to operate has long been a priority. But in most places, government policies for low or zero-carbon buildings still do not fully – if at all – consider the so-called hidden17 or embodied18 emissions. These result from the extraction and production of building materials, such as cement, and the construction process itself. Green-building certification schemes too have long overlooked them. Buildings today are usually built to last notably shorter periods of time than they used to be. If the typical lifespan19 of a traditional building of stone, brick and timber saw first repairs needed after 60 years, modern buildings have deteriorated twice as fast. Significant carbon savings could be achieved by returning to more robust and adaptable construction.

When the built-to-last principle20 proves impractical, however, buildings designed for a shorter lifespan can still be made more sustainable, provided a whole-life carbon approach is adopted and the components and materials used are easy to dismantle and reuse. A surge in innovation21 in recent years has seen a rise in the use of wood and other bio-based materials22 and sustainable design principles, from the circular economy23 to the idea of “cradle-to-cradle”24 production and manufacturing, which defines waste as a resource25 and aims to perpetuate recycling. L'Innesto26 in Milan, for example, has been promoted as a showcase for the city’s sustainability strategies, and is set to be Italy’s first zero-emissions social housing. This project ticks all kinds of boxes: construction will involve minimal soil excavation and bio-sourced building materials with lots of greenery and very little space for cars. Internal heating systems will be powered by renewable energy sources – and more. The problem, though, is that even L'Innesto will only be fully carbon-neutral 30 years after its construction. The project, like many others, relies on carbon offsetting27 to achieve its zerocarbon credentials. When the French architects Anne Lacaton and Jean-Philippe Vassal won the Pritzker Prize this year, their victory was hailed as a turning point28. They have earned a reputation for turning down commissions29 or proving to city councils why refurbishment30 would be better – and cheaper – than building something new. They remain outliers though. For the most part, building greener still involves actual construction. Make no mistake. Green projects such as L'Innesto becoming the norm would be a big step forward. But there is no getting around the fact that three decades to carbon neutrality is a long time in the fight against climate change. This is the industry’s inconvenient truth. The climate crisis is, in no small part, a product of our voracious appetite to build. It is not something, as climate activist Greta Thunberg has pointed out31, that we can simply build our way out of. We cannot afford to only build greener. We need to build less.

intelligent glass solutions | spring 2022

143

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

Sources: 1. https://ukcop26.org/the-conference/presidencyprogramme/

7. https://www.sheffield.ac.uk/architecture/news/ interview-professor-fionn-stevenson

Decarbonising-Construction_building-a-new-netzero-industry_20210923.pdf

2. https://globalabc.org/sites/default/ files/2021-10/2021%20Buildings-GSR%20-%20 Executive%20Summary%20ENG.pdf

8. https://www.buildingsandcities.org/insights/ commentaries/climate-architecture-education.html 9. www.architectscan.org

14. https://theconversation.com/cities-and-climatechange-why-low-rise-buildings-are-the-future-notskyscrapers-170673

3. https://www.thetimes.co.uk/article/demolishing50-000-buildings-a-year-is-a-national-disgracewbrf09952

10. www.architectsdeclare.com

4. www.mcdonough.com 5. www.worldgbc.org 6. https://theconversation.com/refurbishing-oldbuildings-reduces-emissions-but-outdated-tax-ratesmake-it-expensive-125892

144

11. https://theconversation.com/uk-plans-to-slashcarbon-emissions-68-by-2030-how-bankingbuilding-and-borrowing-can-help-151043 12. https://www.architectsjournal.co.uk/news/ retrofirst 13. https://www.raeng.org.uk/RAE/media/ General/Policy/Net%20Zero/NEPC-Policy-Report_

intelligent glass solutions | spring 2022

15. https://www.researchgate.net/ publication/279711810_Life-cycle_analysis_of_the_ built_environment 16. https://www.ukgbc.org/wp-content/ uploads/2019/04/Net-Zero-Carbon-Buildings-Aframework-definition.pdf 17. https://www.reutersevents.com/sustainability/ building-sector-takes-concrete-steps-addresshidden-emissions

SUSTAINABLE TECHNOLOGIES AND TRENDS GAINING TRACTION

Sustainable building materials can only go so far in reducing the sector’s emissions. Image by Avel Chuklanov on Unsplash

Johannes Novy Senior Lecturer in Urban Planning, School of Architecture and Cities, University of Westminster Johannes studied urban planning and urban studies in Germany, Italy and the United States and holds a PhD in Urban Planning from Columbia University, New York. His research interests cover urban and planning theory, urban (development) politics, urban tourism and leisure consumption. Previous positions he held include a guest professorship at the Brandenburg University of Technology CottbusSenftenberg (2013-2015), a visiting professorship at the Politecnico di Milano (2014) and, most recently, a lectureship at Cardiff University (20152018), where he acted as course director of the BSc Urban Planning & Development programme. Some of his most recent publications include the co-edited volume "Protest and Resistance in the Tourist City" (Routledge, 2016) as well as the journal article "'Destination’ Berlin Revisited. From (New) Tourism towards a Pentagon of Mobility and Place Consumption” (Tourism Geographies, 2016). Novy is a member of the

Berlin-based urbanist collective u-Lab, Studio für Stadt und Raumprozesse and regularly teaches at Université Paris 1 PanthéonSorbonne in Paris. In addition to teaching and research, he enjoys working as a consultant and advisor for public, private and non-profit organisations in the realms of urban and tourism development, planning, and policy.

This story is part of The Conversation’s coverage on COP26, the Glasgow climate conference, by experts from around the world. Amid a rising tide of climate news and stories, The Conversation is here to clear the air and make sure you get information you can trust. Discover more here: https://page.theconversation.com/ cop26-glasgow-2021-climate-change-summit/

This article is published in collaboration with The Conversation: www.theconversation.com

18. https://www.ucl.ac.uk/engineering-exchange/ sites/engineering-exchange/files/fact-sheetembodied-carbon-social-housing.pdf 19. https://www.architectmagazine.com/technology/ inside-the-gettys-initiative-to-save-modernarchitecture_o 20. https://www.taylorfrancis.com/chapters/ mono/10.4324/9780429346712-4/built-last-david-che shire?context=ubx&refId=d10efbfb-c188-46cd-a187f827f8fc32bb 21. https://theconversation.com/bendable-concreteand-other-co2-infused-cement-mixes-coulddramatically-cut-global-emissions-152544 22. https://www.archdaily.com/893552/8-

biodegradable-materials-the-construction-industryneeds-to-know-about 23. https://www.designingbuildings.co.uk/wiki/ Circular_economy 24. https://www.c2ccertified.org/get-certified/ product-certification 25. https://sustainabilityguide.eu/methods/cradleto-cradle/#:%7E:text=Cradle%20to%20Cradle%20 (C2C)%20is,right%20thing%20from%20the%20 beginning.&text=C2C%20methodology%20 builds%20on%20the,in%20a%20new%20 product%20cycle. 26. https://www.c40reinventingcities.org/en/ professionals/winning-projects/scalo-greco-

breda-1276.html 27. https://www.designingbuildings.co.uk/wiki/ Carbon_offsetting 28. https://www.theguardian.com/ artanddesign/2021/mar/16/lacaton-vassal-unflashyfrench-architectures-pritzker-prize 29. https://www.lacatonvassal.com/index. php?idp=37# 30. https://theconversation.com/lacaton-andvassal-how-this-years-pritzker-prize-could-spark-anarchitectural-revolution-157636 31. https://awpc.cattcenter.iastate.edu/2019/12/02/ acceptance-speech-at-the-2019-goldene-kameraawards-march-30-2019/

intelligent glass solutions | spring 2022

145

THE GLASS WORD

XXXX

Klaus Lother

146

intelligent glass solutions | spring 2022

THE GLASS WORD

Klaus Lother

XXXX

A true visionary, in his own words

IGS Interviews

Lother “It is in this realm of seeming impossibility that innovation is born and nurtured, where our team and professionals thrive to deliver advanced technologies, ground-breaking engineering and high-performance façades”

intelligent glass solutions | spring 2022

147

THE GLASS WORD

Klaus Lother

The Helix www.aboutamazon.com

148

intelligent glass solutions | spring 2022

THE GLASS WORD

Klaus Lother

In this edition of the Glass Word, IGS Magazine’s Lewis Wilson sits down with Klaus Lother, the charismatic CEO of Permasteelisa Group. He imparts unparalleled wisdom as we explore his thoughts on climate change, competition, pioneering façade design and engineering and gain exclusive insights into past, present and future projects from this prolific group.

1. In such a competitive market, how does Permasteelisa Group maintain its position in the industry and differentiate itself from the competition? In the last few years, our Group has pursued a strategy in line with its founding values: technology, quality, innovation, and excellence in project management. We focus our efforts on the acquisition of projects which demand our expertise, experience and the leadingedge approach of Permasteelisa. In this market sector, we develop advanced technical solutions to first meet our clients’ needs and secondly, to steer us towards further evolution and improvement – in technological aspects as much as in logistics and management. Far from resting on our laurels, we continuously seek innovation through on-going in-house research and partnerships with universities and the like. It is in this spirit of cross-disciplinary collaboration that we are able to progress and deliver technically complex façade solutions that break the mold. Finally, our long-standing commitment towards our clients is based on efficient processes within our organization and ultimately the successful delivery of projects.

intelligent glass solutions | spring 2022

149

THE GLASS WORD

Klaus Lother

We are a truly global company, but this does not mean we are willing to work anywhere and everywhere at any cost. On the contrary, we focus our enterprise and cater to clients in markets that demand the very best facade solutions and where we find opportunities that are suitable for us in terms of technical and commercial characteristics. Projects characterized by high complexity, use of advanced technologies and high-performance standards for which we can make the difference; without the selling price being the most important – and sometimes even - the only driver.

Battersea @ Cesare De Giglio Photography

We keep project execution at the highest levels to provide our clients with the quality they expect while, at the same time, ensuring the generation of vital margins to keep the level of investments high in support of our proprietary cutting-edge technologies. We are paving the way with these strategies firmly in mind and practice, and have already undertaken and implemented measures that are creating an environment that catalyzes the opportunity for growth. 2. Off the back of the UN Climate Change Conference (COP26) in November 2021, there has been a heightened sense of urgency surrounding climate change and sustainability in architecture and façade design. How has/does Permasteelisa Group contribute to a more sustainable future? Indeed, the attention to ecological sustainability for all players in the construction industry has become increasingly relevant and urgent in recent years. Developing an “Environmental Product Declaration” for our curtain wall systems is only the tip of the iceberg in our efforts to reduce our impact on the environment. Permasteelisa has always stood out for its commitment to ecosustainability; the use of sustainable materials and processes, an unwavering commitment to the development of solutions to guarantee energy savings, making more livable buildings for occupants and, finally, improving the quality of the world in which we live. We are constantly working to improve our façades, developing technologically advanced 150

intelligent glass solutions | spring 2022

THE GLASS WORD

Klaus Lother

solutions that allow the achievement of outstanding thermal, acoustic and safety performances, meeting, at the same time, the aesthetic goals of architects and clients. It is no coincidence that many of the projects we are involved in are able to accomplish, not only environmental certifications like LEED and BREEAM, but also the WELL certification which is intended to monitor the quality of environments for building occupants. We are also actively supporting our clients in reducing embodied carbon through our façades, as well as through the calculation of operational and end-of-life carbon emissions over the lifetime of their buildings. It is this holistic approach to decarbonisation, one that encompasses the entire supply chain, all project stakeholders and end users, that I believe is necessary if we are to make significant strides towards achieving the ambitious targets driven by the global Paris agreement, guided by policies like the ‘Green Deal’ and aligned at the global level with the UN’s 2030 sustainable development goals. 3. Permasteelisa Group are pioneering research on the sustainable design of buildings and the development of façade components and systems to achieve this. Can you give us a peak into the current developments that the group is undertaking in terms of alternative materials? The popularity of mass timber (solid laminate timber systems) has grown substantially in contemporary architecture. This, I believe, can be attributed to a combination of factors including, but not limited to, the climate crisis, net-zero targets and a drive towards creating a circular economy in the construction industry. We are currently working on Google KGX1 King’s Cross in London, one of the world’s largest timber and glass façade projects. Designed by BIG and Heatherwick Studio, the aptly named ‘landscraper’ reflects Google’s unique approach to building large-scale headquarters in an urban environment - one that called on our expertise and innovation to design and engineer a façade surface of 23,367sqm for the 50m high and 330m long development. The complex building intelligent glass solutions | spring 2022

151

THE GLASS WORD

Klaus Lother

152

intelligent glass solutions | spring 2022

THE GLASS WORD

Klaus Lother

accommodates numerous terraces and gardens that required sophisticated façade constructions such as timber mullions spanning across three floors. To give you a peak into the design, the facades of the east and west sides will consist of approximately 950 cross-laminated timber mullions (up to 10m high) with more than 90 different crosssections and two stacked, heat strengthened triple glazed units each.

4. Can you share with our readers a couple of examples of innovative projects from the Permasteelisa Group portfolio where your high-performance façade systems and advanced technologies have been used and the benefits they imparted on the projects? Technology is not an end-goal in itself – it is a way to improve the quality of life, and at Permasteelisa Group we know how integral our products are to reducing the carbon footprint of modern cities. The difference between an advanced façade and an outdated low-tech system can be vast, not only from an aesthetic viewpoint, but also from, more importantly, an ecological perspective. That’s why we constantly focus our efforts on improving our systems to produce more efficient, ‘better’ performing building envelopes. I can mention, for example, 22 Bishopsgate in London. At a height of 278 m, it is the tallest skyscraper in the City of London and the tallest skyscraper worldwide that features a particularly sustainable Closed Cavity Façade (CCF). Our German brand Gartner cladded the office tower with 67,000 sqm of closed double-skin façade with story-high units that are limited to a minimum depth, not exceeding 250 mm. The closed cavity of the highly transparent glass units accommodates motorized dual-color venetian blinds, providing sun and glare protection. The storyhigh (4,040 mm / 159 1/16”, 3,550 mm / 139 49/64” or 3,890 mm / 153 5/32”) façade units with their individual widths feature structural glazing sealant and Low-E coating on the inside and LSG panes with selective coating on the outside which are glued directly to the thermally broken framework without carrier frame. intelligent glass solutions | spring 2022

153

THE GLASS WORD

Klaus Lother

Battersea @ Cesare De Giglio Photography

Another project is the iconic Battersea Power Station, where our Italian and British teams of the Permasteelisa brand worked on the two Frank Gehry designed buildings in Phase 3A, designing & engineering, manufacturing and installing around 27,200 sqm of complex 3D shaped unitized façades. The envelope comprises three main elements: customized, unitized glass façade units creating the internal walls of the cladding, unique white surfaces that give the shape to the building and unique spandrel panels. Everything pivots around a key area near the spandrel panel and the transition between this and the vision glass. The levels of complexity presented by this façade were as many and varied as the number of different units required. The innovative design required the engineering and production of around 4,000 unitized panels, with aluminum profiles equipped with double-glazed or opaque infills, all different from each other and openable both with a folding or sliding panel. The undulating shape of the façade required about 3,300 aluminum closed infill white “boxes”, defined by a non-repetitive, customized shape. These boxes create the undulating and sinuous shape desired by the architect. 154

Battersea @ Cesare De Giglio Photography

intelligent glass solutions | spring 2022

The extreme complexity of the façade of Prospect Place at the Battersea Power Station was not only geometrical but also logistical. The varying typologies of panels needed to arrive on site at the right time and be stored in the right position to then facilitate the final installation. In such a vibrant construction site, where many different players are at work in

THE GLASS WORD

Klaus Lother

the same area, being able to perform check lists and controls, hands free, is paramount as it ensures an increased level of safety for the workers. In addition, a perfect integration with our management systems allowed the smooth and timely tracing of each single element of the façade, thus improving quality and efficiency of the operations on site.

5. From Foster + Partners to Herzog & de Meuron, RMJM and Gehry Partners (to name a few), Permasteelisa Group have collaborated with, undeniably, the most influential and prolific architects of our time. What are the challenges of turning the ideas of the world’s greatest architects into reality?

Working with the best architects in the world is certainly a great incentive to push our limits in every project. From the KPF designed One Vanderbilt, to Renzo Piano’s Academy of Motion Pictures and Studio Gang’s Mira Tower, our Group has had to respond to complex designs and ambitious engineering feats. It is in this realm of seeming impossibility that innovation

intelligent glass solutions | spring 2022

155

THE GLASS WORD

Klaus Lother

Photo by NASA on Unsplash

is born and nurtured, where our team and professionals thrive to deliver advanced technologies, ground-breaking engineering and high-performance façades. The Group of today is the result of a process of continuous improvement that underpins all our daily activities, at every level of the hierarchy. Moreover, being a global Group allows us to work with the best professionals in our industry on every project, everywhere in the world. The passion for knowledge and technical excellence is what energises all our employees, and what makes us love our job and all our projects. 6. Permasteelisa Group has had success across the globe, from Asia to Europe, the Middle-East and US, your façade systems and technology are visible (and sometimes invisible) in projects dotted across 4 continents. What do you attribute this global success and expansion to? Through our international presence we can offer local experience coupled with global expertise from all our Group companies. Permasteelisa brings proficiency and ingenuity 156

to all projects, in particular when dealing with special feature buildings and advanced façades. Beginning from the design and development phases, all the way to successful completion, we always aim to achieve or exceed the client’s highest expectations. In essence, our global success can be attributed to a philosophy of never becoming complacent, always pushing the envelope (so to speak) in all aspects of our company. We recognise the dynamic momentum and shifting needs of architects, developers and the construction industry as a whole. Ensuring we address current challenges and provide viable solutions ensures our expertise are not only needed across the globe, but affect change for a better future. 7. COVID-19 has, to say the least, been highly disruptive to the construction industry over the past couple of years. In your view, what effects has the pandemic had on the industry? And how do we collectively overcome the unprecedented challenges that this pandemic has created? To quote Steve Jobs, “innovation is the ability

intelligent glass solutions | spring 2022

to see change as an opportunity – not a threat”. The pandemic has forced us to take a hard look at the way we operate; from developing new processes, to re-evaluating working environments and the way we connect with clients and colleagues, the key has been adaptability. Just as we respond to and solve complex engineering challenges, we have had to adjust to this ‘new’ working climate. It has also had an impact on building design trends; it seems to have heightened the collective consciousness to design more practical, modular structures that are adaptive and circular. Of course, COVID has also led to some delays in the development of many projects around the globe due to the halting of construction sites during lock-downs, and will probably have impacts in the long term on the cost of raw materials. That said, thanks to our strong solidarity, agile approach and promptness to put in place home working for our employees, we have been able to overcome the initial difficulties and keep on developing projects with the usual quality and attention to time schedules.

THE GLASS WORD

Klaus Lother

8. Under the Permasteelisa Group banner, there are 3 brands (Permasteelisa, Gartner and Scheldebouw). How do these brands work together and what are the benefits of this strategic synergy?

The three brands represent 3 different and particular souls inside our Group, all sharing the same technical knowledge, quality and competence. They work in synergy and frequently together on some projects, which allows our group to offer unique resources to our clients to best fit the needs of any job developed within and by the Group. 9. Permasteelisa Group are one of the most accomplished global contractors of our generation with a reputation for delivering imaginative and moldbreaking building envelopes. What is the next step for the company and what projects can we look forward to in the near future?

We are currently working on a number of exciting projects that I am honored to share with IGS readers. The Helix is a tree-covered glass structure and part of the PenPlace development in Virginia. The design of the tower, by NBBJ, is inspired by “biophilia” – intended to reflect humanity’s innate connection to nature. The Helix offers a variety of alternative work environments for Amazon employees amidst lush gardens and flourishing trees native to the region. A true double helix in shape and structure, it features two walkable paths of landscaped terrain that spiral up the outside of the building, featuring plants found in Virginia’s Blue Ridge Mountains. Among other scopes of work, Permasteelisa

The Helix www.aboutamazon.com

intelligent glass solutions | spring 2022

157

THE GLASS WORD

Klaus Lother

Group is designing, engineering, manufacturing and installing a steel and glass ribbon façade and skylight. It includes a 11,500 sqm ribbon façade consisting of 4,800 triangular façade units with triple glazed glass and 635 mega panels, a steelaluminium hybrid structure, up to 12 m long and approximately. 2.5 m high and curved. The project is also LEED Platinum targeted and will run on 100% renewable energy. Located at the corner of Congress Street and Boston Wharf Road, Boston Seaport Block L5 (deisgned by architects Gensler and Henning Larson), is primarily dedicated for office use but

includes space for a performing arts center and a penthouse. The design was conceived to emphasize human-centricity with amenities ranging from several outdoor terraces to a street-level interior public promenade. The tower geometry consists of sloped unitized façades on three sides either at a 15° angle step back per floor on the west and north façade or at a 20° angle on the east one. The complex aluminum-and-glass envelope is composed of multi-layered elements to create visible façade depth. The tower fins have an inset aluminum panel with a custom finish that matches the podium terracotta.

158

intelligent glass solutions | spring 2022

In Frankfurt’s banking district, a new complex of four high-rise buildings with a shared, publicly accessible podium is developing. A joint venture from architects UNStudio, HPP Architekten and Groß & Partner, FOUR Frankfurt is intended to revitalize this quarter with a unique mix of offices, retail, apartments, hotels and dining. The two residential towers, 178 m and 125 m high, will be among the tallest in Germany and will be clad with façades in dynamic shapes designed, engineered, manufactured and installed by Permasteelisa Group.

THE GLASS WORD

Klaus Lother

Klaus Lother, CEO, Permasteelisa Group A German national, Klaus brings 28 years of industry experience to the position, primarily acquired in management roles at Permasteelisa Group. Klaus joined Josef Gartner GmbH as an engineer in 1993 and was appointed CEO in 2002. More recently, he served as Permasteelisa Group CEO for the European region. Since 2019, Klaus has been the Permasteelisa Group CEO, bringing his proven management skills, a deep understanding of the Curtain Wall industry, and unparalleled knowledge of the group’s values, history, processes, and knowhow. He graduated in Mechanical Engineering, Production Technology (Dipl.-Ing.) at the Technical University in Munich.

intelligent glass solutions | spring 2022

159

AUTHORS DETAILS SPRING 2022 LAURA KARNATH Walter P Moore Senior Associate, Senior Enclosure Technical Designer 1301 McKinney, Suite 1100, Houston, TX 77010, United States info@walterpmoore.com +1 713 630 7300 www.walterpmoore.com SOPHIE PENNETIER Enclos Associate Director, Special Projects 304 S Broadway Suite 520 Los Angeles, CA 90013 curtainwall@enclos.com +1 213 284 3530 www.enclos.com GRAHAM COULT Eckersley O'Callaghan Technical Director 236 Gray's Inn Road, London, WC1X 8HB, United Kingdom london@eocengineers.com +44 (0) 20 7354 5402 www.eocengineers.com GIANLUCA RAPONE FMDC Associate and Sustainability Lead 5A/B Scriptor Court, 155-157 Farringdon Road London EC1R 3AD, United Kingdom +44 20 3735 5211 www.fmdc.co.uk

160

VALÉRIE HAYEZ High Performance Building Solutions at Dow Global Façade Engineering & Architectural Design Engineer Bachtobelstrasse 3, 8810 Horgen, Switzerland +41 44 728 21 11 www.dow.com/ carbonneutralsilicones GLASS FOR EUROPE rue Belliard 199/33 1040 Brussels, Belgium info@glassforeurope.com +32 2 538 43 77 www.glassforeurope.com PROF. PENG SHOU China Triumph International Engineering Co (CTIEC) Chairman 26F Bldg. Zhongqi No. 2000 North Zhongshan Road, Putuo District Shanghai, Shanghai 200063 China shanghai@ctiec.net +86 2152 916 280 www.ctiec.net SOL CAMACHO RADDAR Founder and Director Alameda Itu 1063. Cj 32 Sao Paulo, SP - Brasil 01421-001 info@raddar.org +55 11 2308 4840 www.raddar.org

intelligent glass solutions | spring 2022

OKALUX Am Jösperhecklein 1 D-97828 Marktheidenfeld, Germany info@okalux.de +49 9391 9000 www.okalux.com ANDREAS SCHEIB Glas Trösch Chief Communication Officer Glas Trösch Holding AG Industriestrasse 29 CH-4922 Bützberg, Switzerland info@glastroesch.com +41 800 118 851 www.glastroesch.com AMBER GUPTA Onyx Solar Energy Accredited Professional C/ Río Cea 1, 46 05004 Ávila, Spain info@onyxsolar.com +34 920 21 00 50 www.onyxsolar.com EDGETECH EUROPE Edgetech Europe GmbH Gladbacher Strasse 23 Heinsberg, 52525, Germany +49 (0)2452 96491 0 www.quanex.com

ASTON FULLER Glass Futures General Manager Glass Futures Limited 9 Churchill Way Chapeltown Sheffield S35 2PY England, United Kingdom info@glass-futures.org +44 114 290 1860 www.glass-futures.org ERIK MUIJSENBERG Glass Service Vice President Rokytnice 60, Rokytnice, 755 01 Vsetín, Czech Republic info@gsl.cz +420 571 498 511 www.gsl.cz JOHANNES NOVY School of Architecture and Cities, University of Westminster Senior Lecturer in Urban Planning 35 Marylebone Road London GB NW1 5LS J.Novy@westminster.ac.uk +44 (0)20 7911 5000 www.westminster.ac.uk KLAUS LOTHER Permasteelisa Group CEO Viale E. Mattei 21/23 | 31029 Vittorio Veneto, Treviso, Italy info@permasteelisagroup.com +39 0438 50 5000 www.permasteelisagroup.com

XXXX

New experience is here. Visit us at www.permasteelisagroup.com

intelligent glass solutions | spring 2022

161

XXXX

22 BISHOPSGATE, LONDON ARCHITECT: PLP ARCHITECTURE FACADE: JOSEF GARTNER GMBH 22 BISHOPSGATE, LONDON ARCHITECT: PLP ARCHITECTURE FACADE: JOSEF GARTNER GMBH

GLASS BONDING IS OUR PASSION GLASS BONDING IS OUR PASSION Sika offers full range sealing and bonding solutions for insulated glass manufacturing, structural glazing and weathering sealing thereby ensuring system compatibility. With its profound competence in opaque and glass facades alike, Sika is the ideal partner for planners and applicators of all kind on building envelopes. Sika offers full range sealing and bonding solutions for insulated glass manufacturing, structural glazing and weathering sealing thereby ensuring system compatibility. With its profound competence Contact usand now. in opaque glass facades alike, Sika is the ideal partner for planners and applicators of all kind on building envelopes. Contact us now.

162

Sika Services AG FFI Facade · Fenestration · Insulating Glass Tueffenwies 16 · CH-8048 Zurich · Switzerland Tel. +41 (0)58 436 40 40 · Fax +41 (0)58 436 55 30 www.sika.com/facade Sika Services AG FFI Facade · Fenestration · Insulating Glass Tueffenwies 16 · CH-8048 Zurich · Switzerland Tel. +41 (0)58 436 40 40 · Fax +41 (0)58 436 55 30 intelligent glass solutions | spring 2022 www.sika.com/facade

IGS Magazine Spring 2022: Decarbonising the Glass Industry

Articles inside

WE CAN’T AFFORD TO JUST BUILD GREENER WE MUST BUILD LESS Johannes Novy - Senior Lecturer in Urban Planning, School of Architecture and Cities, University of Westminster

FLEXIBLE SPACERS: MORE EFFICIENCY IN THE

NET-POSITIVE GLASS BUILDINGS OF THE FUTURE Amber Gupta - Accredited Professional, Onyx Solar Energy

FLAT GLASS: LEADING THE SUSTAINABILITY RACE Inspired by a speech given by Mr. Philippe Bastien, Chairman, Glass for Europe at the Palace of Nations in Geneve

A POWERFUL COMBINATION: GLASS AND MODULAR TIMBER Okalux

DESIGN AND ENGINEER WITH LESS IMPACT: CARBON NEUTRAL

CARBON-LED FAÇADE DESIGN Gianluca Rapone - Associate and Sustainability Lead, FMDC

DEVELOPMENT AND TRENDS OF GLASS INNOVATION UNDER

REFLECTIONS ON REFLECTION: GLASS IN ARCHITECTURE Sol Camacho – Founder and Director, RADDAR

THE NEW JEWEL IN THE CROWN OF DUBLIN Andreas Scheib - Chief Communication Officer, Glas Trösch Group

ACHIEVING A VIRTUOUS CIRCLE: DRIVING CIRCULARITY