In accordance with ISO 14021
The result presented in this document are taken from an LCA performed in accordance with ISO 14040:2006 and ISO 14044:2006 LCA standards. The document also follows ISO 14021:2016.
Publication date: 2025-02-21
Version: 1.0
Document number: ESD-020
Type of ESD: ESD of multiple products based on worst-case results of the included products
Owner of the document: Elcowire Rail GmbH
Lichtöcherberg 40
D-06333 Hettstedt, Germany
The document owner has the sole ownership and responsibility.
Contact information:
Head of Product Management: Robert Gehrmann
+49 3476 8714 56
robert.gehrmann@elcowire.com
Sustainability Manager: Jonas Ciardi
+46 707 614 726
jonas.ciardi@elcowire.com
Description of the organisation: Elcowire is one of Europe’s largest manufacturers of copper wire rod, wires, stranded conductors, profiles, and overhead catenary systems made from copper, copper alloys, and aluminum, with an annual production of approximately 300,000 metric tonnes. The profiles can be formed into any shape and dimension. Elcowire also produces aluminum conductors, rectangular wire, and profiles for electrical applications.
Elcowire is driven by a commitment to continuous improvement, always keeping the customer at the forefront. This results in high-quality products, reliability, meticulous attention to detail, and a strong technical partnership. The business is organized into five units: Rod, Rail, High Voltage, Specials, and Wire & Strands.
Product-related or management system-related certifications: ISO 9001 and ISO 14001.
Name and location of production site(s): Elcowire Group has production plants in Helsingborg, Sweden and Hettstedt, Germany. This document concerns Elcowire Rail GmbHs production plant in Hettstedt.
This document is the 1st version.
Elcowire offer customers to buy Stranded Wire from OFC with 100% Recycled Copper. Recycled copper is made possible through production by using re-used copper. The result is stranded wire that has a low impact on nature and the climate and with high degree of circularity.
The significantly lower CO2 emissions of the recycled copper are verified through several validation processes. The reporting protocol that was used for verification is the Greenhouse Gas Protocol – Product Life Cycle Accounting and Reporting Standard. The product was also validated and reviewed against the general principles in ISO 14064-3 Standard.
Elcowire applies the Mass Balance Approach (MBA), which enables allocation of specific characteristics (like biobased material or recycled content) to products from a manufacturing process without making complicated changes of the production infrastructure. Thus, copper with different specific characteristics is, within the production environment, mixed causing them to no longer be traceable directly to the source. However, by tracking the amount of each input material and the amount of product output, it is possible to estimate the amount of each input material that is used in the production of the final product.
This document provides information of the environmental impact for Stranded Wire from OFC with 100% Recycled Copper.
In Elcowire’s MBA, the copper cathodes are grouped into three categories (LCC, 100% Recycled Copper and Standard Copper) based on the suppliers’ climate impact cradle-to-suppliers gate with respect to the principles below:
• Principle 1: Copper cathodes, with or without recycled copper, whose climate impact is less than 1.5 kg CO2 eq./kg from cradle-to-supplier’s gate, are categorized as either LCC or Standard Copper.
• Principle 2: Copper cathodes consisting of 100% recycled copper are categorized as 100% Recycled Copper, regardless of the climate impact from cradle-to-suppliers gate.
• Principle 3: Copper cathodes that do not meet the criteria of Principle 1 or Principle 2 are categorized as Standard Copper.
Note that the principles apply for cradle-to-suppliers gate, i.e., the climate impact from transportation of copper cathodes from the suppliers to Elcowire’s production site is outside the categorization.
Elcowire collects specific data on cradle-to-suppliers gate climate impact in kg CO2 eq./kg copper cathode, recycled content and transportation from supplier to Elcowire’s production site. If the supplier cannot provide specific data for cradle-to-suppliers gate climate impact, global averages are assumed according to the International Copper Association. The same principle applies for recycled content where Elcowire assumes a recycled content of zero if the supplier cannot support with a verification. For Elcowire, materials are classified as recycled content if they originate from or have previously been designated as waste material. The definition includes activities for waste management and recycling but excludes production waste that is reutilized within the same production process that generated it, as well as reconditioned and repaired products that remain in active use.
The MBA is based on planned volumes for 2024 while the actual volumes is followed up via book-keeping with a reconciliation period of three months. The actual volumes are scaled up year-to-year to compare the climate impact between planned and actual volumes. If there is a mismatch of 10 % for the climate impacts, a recalculation of the mass balance is actualized. However, the copper cathodes are contractually purchased on an annual basis, and it is expected that deviations are small.
As described earlier, the copper cathodes are sorted into the three categories (LCC, 100% Recycled Copper, and Standard Copper) with respect to the principles above. Subsequently, weighted averages are derived for each category, considering the cradle-to-suppliers gate climate impact, emissions related to transportation from the supplier to Elcowire’s production site, and the planned volumes for 2024. The recycled content for each category is calculated by dividing the recycled fraction with the total volume of copper cathodes per category.
Product name: Stranded wires (CuMg0.2 to CuMg0.5) from OFC with 100% recycled copper from Brixlegg
Product description: Stranded wires, such as catenary wires as well as flexible cable conductors, are a part of the overhead contact line system. Their main function is basically to provide electrical power to trains. Furthermore, catenary wires and the droppers support the contact wire and ensure that it remains as straight as possible
Similar to contact wires, catenary wires are designed for use in various overhead lines systems that are designed for different train speeds and different electrical power systems (AC or DC).
Catenary wires as well as flexible cable conductors are characterized through their mechanical and electrical properties in terms of break load and electrical resistance.
Typically, cable conductors are made of pure copper (Cu-ETP) or bronze BzII (CuMg). But other alloys can be used as well, such as CuSn alloys.
Their electrical and mechanical properties are specified in national and international standards.
However, the construction of the stranded wires can vary to a large extend depending on the number of individual wires that are used.
Catenary wires range from 7 to 61 individual wires (see Table 1) with a nominal cross section from 10 mm2 to 500 mm2. Flexible cable conductors consist of 49 to 637 individual wires with a nominal cross section from 16 mm2 to 300 mm2
Figures 1 to 7 give an exemplarily overview of the appearance of different stranded wires (catenary wires and flexible cable conductors).
Product specifications:
• IEC 63190; Railway applications – Fixed installations – Electric traction – Copper and copper alloy catenary wires for overhead contact line systems
• DIN 48200 Teil 1; Drähte für Leitungsseile – Drähte aus Kupfer
• DIN 48200 Teil 2; Drähte für Leitungsseile – Drähte aus Kupfer-Knetlegierungen (Bz)
• DIN 48201 Teil 1; Leitungsseile – Seile aus Kupfer
• DIN 48201 Teil 2; Leitungsseile – Seile aus Kupfer-Knetlegierungen (Bz)
• DIN 48203 Teil 1; Drähte und Seile für Leitungen aus Kupfer; Technische Lieferbedingungen
• DIN 48203 Teil 2; Drähte und Seile für Leitungen aus Kupfer-Knetlegierungen (Bz); Technische Lieferbedingungen
• DIN 43138; Flexible Seile für Fahrleitungsanlagen und Rückleitungen
Type of ESD: ESD of multiple products based on worst-case results of the included products.
Declared unit: 1 kg of stranded wire (CuMg0.5) from OFC based on 100% recycled copper Brixlegg.
Packaging material consists of wood drums, pallets, wooden boxes and coverings, plastics and cardboards.
Time representativeness: Process data are representative for 2023, while the procurement of copper cathodes is based on planned volumes for 2024.
Databases and LCA software used: Ecoinvent 3.8 and SimaPro 9.3.0.3
Description of system boundaries: Cradle to gate with modules C1–C4 and module D (A1–A3 + C + D)1. See Figure 2 for a representation of the system boundaries and modules declared.
System boundaries:
Figure 1 Modules declared (G = generic data, S = specific data).
Estimates and assumptions: Electricity, heat, chemicals, water usage, waste, and packaging materials are calculated as weighted averages based on process data for 2023. The distance for transportation of packaging materials was assumed to 500 km. Road transportation was assumed to be carried out with a EURO VI truck, while train transportation was assumed to be carried out with freight train in Europe. The electricity in core manufacturing process (A3) was modelled with a market process representing the production mix in Germany 2023.
Cut off criteria: All known inputs and outputs are included in the system boundary.
Data quality: The data quality for global warming potential for the copper cathodes cradle-to-suppliers gate can be considered good. For the magnesium, the data quality can be considered fair using only global averages. Data
1 Equal to EPDs produced in accordance with the EN 15804:2012+A2:2019 standard.
quality for waste can be described as fair. Upstream waste from copper production in A1 is based on reference values from International Copper Association as no specific data was available. The specific data for the core manufacturing process in A3 has been done thoroughly including all relevant flows and should be considered very good.
Dangerous substances: No dangerous substances from the candidate list of SVHC for authorization are included in the products.
Module C and D are calculated based on a scenario.
Module C – Only copper is taken into consideration in module C, therefore there is no impact in C1.
The copper is assumed to be transported 100 kilometres by a EURO VI truck from the site to a recycling centre (C2). As only the copper is being considered, no processing before recycling is necessary. In C3, the packaging materials made of wood, paper and plastic is assumed to be incinerated.
No disposal occurs for the products, thus there is no impact in C4.
Module D – All copper used in the declared product consist of recycled material, hence no benefits beyond system boundaries are calculated. For the packaging material, it is assumed that it goes to incineration and energy recovered. The recovered energy is assumed to contribute with electricity to the European electricity grid. Thus, the packaging contributes positively beyond the system boundary. For the magnesium fraction, no benefit was given to the system.
The results for the declared product are presented in the tables below. For module A1-A3, the climate impact for the GWP-GHG indicator is equal to 1.76 kgCO2e/declared unit.
Results
Acronyms
GWP-fossil = Global Warming Potential fossil fuels; GWP-biogenic = Global Warming Potential biogenic; GWP-luluc = Global Warming Potential land use and land use change; ODP = Depletion potential of the stratospheric ozone layer; AP = Acidification potential, Accumulated Exceedance; EP-freshwater = Eutrophication potential, fraction of nutrients reaching freshwater end compartment; EP-marine = Eutrophication potential, fraction of nutrients reaching marine end compartment; EP-terrestrial = Eutrophication potential, Accumulated Exceedance; POCP = Formation potential of tropospheric ozone; ADP-minerals&metals = Abiotic depletion potential for non-fossil resources; ADP-fossil = Abiotic depletion for fossil resources potential; WDP = Water (user) deprivation potential, deprivation-weighted water consumption
* Disclaimer: The results of this environmental impact indicator shall be used with care as the uncertainties of these results are high or as there is limited experience with the indicator.
Potential environmental impact
Results per kg of stranded wire (CuMg0.5) from OFC based on 100% recycled copper from Brixlegg
2 The indicator includes all greenhouse gases included in GWP-total but excludes biogenic carbon dioxide uptake and emissions and biogenic carbon stored in the product. This indicator is thus almost equal to the GWP indicator originally defined in EN 15804:2012+A1:2013.
Results per kg of stranded wire (CuMg0.5) from OFC based on 100% recycled copper from Brixlegg
Acronyms
PERE = Use of renewable primary energy excluding renewable primary energy resources used as raw materials; PERM = Use of renewable primary energy resources used as raw materials; PERT = Total use of renewable primary energy resources; PENRE = Use of non-renewable primary energy excluding nonrenewable primary energy resources used as raw materials; PENRM = Use of non-renewable primary energy resources used as raw materials; PENRT = Total use of non-renewable primary energy re-sources; SM = Use of secondary material; RSF = Use of renewable secondary fuels; NRSF = Use of non-renewable secondary fuels; FW = Use of net fresh water
Results
Output flows
Results per kg of stranded wire (CuMg0.5) from
Results per kg of stranded wire (CuMg0.5) from OFC based on 100% recycled copper from Brixlegg
3 All waste flows are managed within the system limits in Ecoinvent processes, which is why there is 0 kg of waste under these modules.
4 Biogenic carbon stored in packaging material and as energy is direct balanced out in the module they are manufactured.
• CEN/TC 350, 2019. Sustainability of construction works - Environmental product declarations - Core rules for the product category of construction products. European committee for standardization.
• Ecoinvent
• Elcowire Group, 2024. Accounting and verification process
• Elcowire Group, 2024. Cathode Massbalance HET 2024 - locked version for LCA – 20240917.
• International Copper Association. Copper Environmental Profile.
• International Organization for Standardization, 2006. ISO 14040:2006 Environmental management - Life cycle assessment - Principles and framework.
• International Organization for Standardization, 2006. ISO 14044:2006 Environmental management - Life cycle assessment - Requirements and guidelines
• International Organization for Standardization, 2016. ISO 14021:2016 Environmental labels and declarations - Self-declared environmental claims (Type II environmental labelling)
• Network for Transport Measures, 2024. Default and benchmark transport data.