The Research: 

To identify the key drivers of embodied carbon and the key opportunities to reduce embodied carbon for each product type we read Environmental Product Declarations (EPDs), reviewed literature and data compilations, and conducted manufacturer interviews. The hazards associated with flooring products, the chemicals used to make those materials and the hazards associated with the chemicals used to install those products were collected using InformedTM product guidance and hazard data in the Pharos database. 

Embodied Carbon:

 Our research concluded that flooring products’ embodied carbon impacts are mostly associated with the raw material supply. The biggest opportunities to reduce embodied carbon in flooring comes from choosing a different product type that uses less impactful raw materials as well as products with longer service life. Carpet was consistently the most impactful product type due in part to its short service life. Plant-based flooring products, such as wood and natural cork, were consistently the least impactful.

Material Health:

 Not surprisingly, the biggest opportunities to avoid chemicals of concern in flooring come from choosing a product type with typically fewer chemicals of concern. Products made from plastic, such as vinyl, nylon, or polyurethane tend to use more hazardous chemicals during manufacturing, installation, use, and end of life, than mineral or plant-based products. Selecting a product that is yellow or above in InformedTM color ranking Flooring Guidance, such as wood or linoleum, or even a non-vinyl resilient flooring will minimize the use of hazardous chemicals. Products in the red zone such as vinyl and carpet, should be avoided.

Conclusion: 

When we looked at the opportunities to improve embodied carbon and improve material health for flooring we found that they were largely complementary.

• Use flooring with a long service life. Avoid products with a short service life, like carpet, and select a product with a long service life, like wood. 
• Choose biobased product types. Linoleum, wood, and cork are all flooring product types that were identified as both resulting in lower embodied carbon and safer in terms of material health. 
• If you must use carpet, avoid use of virgin nylon carpet product types. While carpet generally can contain more chemicals of concern than other product types, carpet made with virgin nylon as a generic product type was identified as having the highest embodied carbon within the flooring category. 
• Use circular and safe materials. Use recycled content from known sources. Prefer products that have been tested for these chemicals and have below detectable levels or below levels that would be found in virgin resin content for these materials. 

These findings highlight the importance of pre-emptive design.  Parallel to the way we conduct early modeling for energy or water use, the industry needs to model for embodied carbon and material health. A materials modeling approach–where the entire team is engaged early – before design development or construction development – will enable educated decisions before the design is set.  Use HBN’s Embodied Carbon and Material health in Flooring and Drywall report and tools like Informed™ and the Carbon Smart Materials Palette to select typically healthier, low-carbon building product options.

The analysis found that both SPF and fiberglass release pollution into BIPOC communities over their life cycles, but SPF carries a much heavier pollution burden. The combined population surrounding the facilities that manufacture the key ingredient of SPF has almost double the percentage of Latino people compared to the U.S. overall. These facilities reported releasing an average of about 560,000 pounds of related hazardous chemicals every year and have a history of noncompliance with EPA regulations. Our previous research also found that spray foam has significant hazardous chemical concerns during installation and use in buildings.

Regarding embodied carbon, while the specifics vary, studies (such as here, here, and here) consistently show that closed cell SPF has significantly higher embodied carbon per R-value than fiberglass insulation. Further, SPF is made from almost entirely fossil fuel-derived inputs, with no recovery, reuse, or recycling of the material—necessitating continued extraction and refining of fossil fuels to produce this insulation product. Overall, comparing material health, environmental justice, and embodied carbon impacts between SPF and fiberglass, fiberglass is preferable on all accounts. 

However, fiberglass manufacturing still releases hazardous pollution into communities who are disproportionately BIPOC and/or low income, and many fiberglass facilities have exhibited regular noncompliance with EPA regulations. Fiberglass manufacturers can reduce and eliminate such pollution by using less hazardous chemistries. For example, all four U.S. manufacturers reported reduced releases of formaldehyde by changing to safer binder formulations for many of their products between 2002 and 2015.   

Why It Matters
As laid out in the Equitable and Just National Climate Platform:

“To achieve our [climate] goals, we will need to overcome past failures that have led us to the crisis conditions we face today. Past failures include the perpetuation of systemic inequalities that have left communities of color, tribal communities, and low-income communities exposed to the highest levels of toxic pollution and the most burdened and affected by climate change. The defining environmental crisis of our time now demands an urgency to act. Yet this urgency must not displace or abandon the fundamental principles of democracy and justice…Unless justice and equity are central components of our climate agenda, the inequality of the carbon-based economy will be replicated in the new economy.”

To truly be part of a just and equitable transition to a clean economy, climate solutions like building insulation must advance the well-being of BIPOC and low-income communities. We recommend that embodied chemical and environmental justice impacts drive material decision-making on par with consideration of GHG emissions. 

Your Action Today = Healthier, More Just Future
In general, there are significant opportunities to improve the life cycle of building insulation materials through avoiding hazardous chemicals, implementing circularity, and taking other actions stemming from the principles of green chemistry and environmental justice.

Manufacturers and policymakers should advance transparency about what is in a product, how and where it is made, and the hazardous releases that occur throughout its life cycle. In the meantime, those who choose building materials can start by avoiding hazardous chemicals in a product’s content to help protect not only building occupants and installers, but also others impacted by those hazardous chemicals throughout the supply chain. Our InformedTM product guidance can help you choose safer materials.

All stakeholders–including manufacturers, policymakers, and those who choose building materials–should support the leadership of frontline communities and make changes to their own practice so that all families have healthy places to live, learn, work, and play.

The original Charter was created in 2004; at that time, HBN joined a broad coalition of grassroots, labor, health, and environmental justice groups in an extensive process initiated by community organizations in Louisville, KY. Louisville’s “Rubbertown” area hosted 11 industrial facilities that released millions of pounds of toxic air emissions every year. The Charter was named in honor of this city and all of the communities across the nation exposed to toxic chemical contamination—starting with the people who are harmed first and worst. We participated in the 2021 update process, supporting the efforts of the most heavily impacted communities to more explicitly address the chemical industry’s massive contribution to the climate crisis, and the need to advance environmental justice in communities who are disproportionately impacted.

The Louisville Charter is a unifying guide for everyone working to ensure that toxic chemicals are no longer a source of harm, from local and national policy-makers and labor organizers, to health care workers and concerned community members, to committed leaders in the building industry. It is meant to be versatile and used in a wide variety of contexts for one overarching purpose: to overhaul chemical policies in favor of safety, health, equity, and justice, and avoid false solutions that simply shift harms to other people and places.

HBN is proud to be a signatory of the Charter and join this diverse and intersectional community of partners  demanding urgent action to protect, strengthen, and restore our most vulnerable communities.

When you shop for a flooring product, what do you consider? Perhaps you think about the look and feel of the product and its durability. You likely also consider the price. The cost of using a material is influenced by the cost to purchase the product itself, the installation cost, maintenance costs, as well as how long the product will last (when you will have to pay to replace it). These are all internalized costs, paid by the building owner. 

These costs alone, however, do not consider the full impacts of materials along their life cycles.  More and more building industry professionals are paying attention to the content of building products and working to avoid hazardous chemicals in an effort to help protect building occupants and installers from health impacts following chemical exposures. To understand the true, full cost of a product, we must look beyond just the monetary cost of purchasing and maintaining a product.

Many of the costs associated with products are more or less hidden when choosing a building material. Just a few of these hidden costs are outlined below.

1. Toxic Chemical Impacts on Human Health: This includes direct medical expenses due to diseases caused or exacerbated by chemical exposures, as well as indirect health-related costs like loss of productivity in work or school and decreased economic productivity in terms of loss of years of life and loss of IQ points. It also includes the immeasurable costs to quality of life and loss of loved ones.
2. Environmental Contamination Costs: Contamination of the environment with toxic chemicals contributes to the human health impacts noted above. In addition, the costs of environmental contamination can include reduced property values in and around contaminated areas, loss of income and food production from the contamination of farms, and the cost of clean up activities (e.g. utilities clean up of water contamination). Less quantifiable costs include damage to wildlife and ecosystems.
3. Climate Change Impacts: Production of chemicals and products is often energy-intensive and based on fossil fuels. Most products contribute to climate change to some extent. Some contribute more than others because of energy use or the release of chemicals with high global warming potential. These greenhouse gas emissions exacerbate climate change, leading to increasingly powerful storms and fires, with increasingly high and recurring costs for recovery. Climate change also magnifies the impacts of toxic chemicals, increasing the human and environmental health costs. 
4. Environmental Injustice: Disproportionately, the health impacts and associated costs throughout the life cycle of products (e.g. during manufacturing and at end of life) fall on  communities of color and low-income communities. The numerical cost of these impacts may not be quantifiable, but the costs to our society are no less clear as a result.

Toxic Chemical Impacts on Human Health
The US Occupational Safety & Health Administration (OSHA) estimates that American workers alone suffer more than 190,000 illnesses and 50,000 deaths per year that are related to chemical exposures. These chemical exposures are tied to cancers, as well as other lung, kidney, heart, stomach, brain, and reproductive diseases.1

While some workers may see greater exposures to hazardous chemicals, all of us are impacted. Many of you are likely familiar with PFAS, aka per- and polyfluoroalkyl substances. PFAS have been used in a wide range of applications, including stain-repellent treatments for carpet and countertop sealers. The widespread use of PFAS has led to extensive contamination of the planet and people. Increasing research and attention to this group of chemicals has led to some quantitative understanding of the costs to society of their use. A recent publication in Environmental Science and Technology outlined some of the true costs of PFAS chemicals. The authors highlight that, “A recent analysis of impacts from PFAS exposure in Europe identified annual direct healthcare expenditures at €52–84 billion. Equivalent health-related costs for the United States, accounting for population size and exchange rate differences, would be $37–59 billion annually.” Importantly, they further call out the fact that, “These costs are not paid by the polluter; they are borne by ordinary people, health care providers, and taxpayers.”2

And this is just the cost of one group of chemicals. Another recent study estimated the cost of US exposures to phthalates, a group of chemicals used to make plastics more flexible, to be approximately $40 billion or more due to loss of economic activity from premature deaths.3 While more research is needed, the scale of these estimated costs is staggering.

Environmental Contamination Costs
The release of PFAS chemicals has contaminated water supplies globally. About two-thirds of the US population receives municipal drinking water that is contaminated with PFAS. Reducing the levels of PFAS in drinking water can be expensive, and none of the methods fully remove PFAS. In the Environmental Science and Technology study mentioned above, the authors note that “following extensive contamination by a PFAS manufacturer in the Cape Fear River watershed, Brunswick County, North Carolina is spending $167.3 million on a reverse osmosis plant and the Cape Fear Public Utility Authority spent $46 million on granular activated carbon filters, with recurring annual costs of $2.9 million. Orange County, California estimates that the infrastructure needed to lower the levels of PFAS in its drinking water to the state’s recommended levels will cost at least $1 billion.” Again, these costs are typically not paid by the polluter but shifted to the public.4

Climate Change Impacts
Chemicals used in the production of some PFAS are ozone depleters and potent greenhouse gases. New research released in September by Toxic-Free Future, Safer Chemicals Healthy Families, and Mind the Store ties the release of one such chemical, HCFC-22, to the production of PFAS used in food packaging. The reported releases of this one chemical from a single facility is equivalent to “emissions from driving 125,000 passenger cars for a year.”5

The costs of climate change impacts are immense. For example, the number of billion-dollar disasters and the total cost of damages due to natural disasters have been skyrocketing. The National Oceanic and Atmospheric Administration describes how climate change contributes to increasing frequency of some extreme weather events with billion-dollar impacts. They outline the broader context of these extreme weather events saying that, “the total cost of U.S. billion-dollar disasters over the last 5 years (2016-2020) exceeds $600 billion, with a 5-year annual cost average of $121.3 billion, both of which are new records. The U.S. billion-dollar disaster damage costs over the last 10-years (2011-2020) were also historically large: at least $890 billion from 135 separate billion-dollar events. Moreover, the losses over the most recent 15 years (2006-2020) are $1.036 trillion in damages from 173 separate billion-dollar disaster events.”6

Figure 1. Billion-dollar Disasters and Costs (1980-2020)7

Environmental Injustice
In the US, communities of color and low-income communities are disproportionately impacted by environmental pollutants.8 These communities often face hazardous releases from multiple sources due to high concentrations of manufacturing facilities near their homes. The area along the Mississippi River between New Orleans and Baton Rouge is known as “Cancer Alley” because of the concentration of industrial activity and the associated elevated cancer risks.9 Figure 2 maps facilities that report to EPA’s Toxics Release Inventory (TRI) in this area. These are facilities that release or manage hazardous chemicals that require reporting to EPA.  

The city of Geismar, LA is home to 18 TRI facilities. These facilities reported a total of over 15 million pounds of on-site releases of hazardous chemicals to air, water, and land in 2019.10 Several of these facilities produce chemicals used in the building product supply chain. Two facilities produce chlorine for internal or external production of PVC, which can be used to make pipes, siding, windows, flooring, and other building products.11 Two other facilities manufacture a key ingredient of spray foam insulation, MDI. Some of these facilities have a history of noncompliance with EPA regulations, one having significant violations for eight of the last twelve quarters and another having significant violations for all twelve of the last twelve quarters.12 Surrounding communities are impacted by regular toxic releases from these facilities and are vulnerable to accidents involving toxic chemicals. For example, an explosion and fire at the vinyl plant in 2012 released thousands of pounds of toxic chemicals, led to a community shelter in place order, and shut down roads and a section of the Mississippi River.13

More than 5,000 people live within three miles of one or more of these four facilities. This community is disproportionately Black — 35% of the population compared to 12% in the US overall. Thirty percent of the population is children, with about 1500 kids under the age of 18. This community has a higher estimated risk of cancer from toxics in the air than most places in the US — almost four times the national average.14

The message we hope you take away from this article is that we must move beyond discussions based purely on the material costs or up-front costs of products. We must all work together to acknowledge and shed light on the true costs that toxic chemicals have within our society and on specific communities. The impacts of hazardous chemicals are, of course, not just monetary –people’s lives are significantly impacted in multiple ways. The current system subsidizes cheap products by robbing individuals of the opportunity for healthy lives and for children to play, and grow up, and enjoy a full and normal life.

Unfortunately, there is not currently enough information available to make detailed cost accounting broadly possible, and no framework exists for accounting for and comparing the full extent of product costs. Transparency about what is in a product, how the product is made, and hazardous emissions – beyond those required to be reported by law – is critical. Programs that place extended responsibility on manufacturers to manage materials at their end of life (as part of extended producer responsibility or EPR)15 can be a starting point for conversations about the full life cycle impacts of products and can help hold manufacturers accountable for a broader array of costs, once they are better understood.

In the meantime, Habitable works to incorporate a life cycle chemical perspective into our safer material recommendations like our Informed™ product guidance and Pharos database. These tools are a work in progress initially focused on avoiding hazardous chemicals in a product’s content. As a starting point, this helps protect not only building occupants and installers, but also others impacted by those hazardous chemicals throughout the supply chain. When hazardous chemicals are used, it is likely that someone throughout the supply chain is impacted. Informed™ can help you choose safer building products based on the information that we have today as we work to expand our incorporation of life cycle chemical impacts into our research and to provide guidance on a broader range of materials.

Habitable looks forward to continuing to identify and provide the critical data needed  to assist in decision making with a more comprehensive view of the true costs of materials, and to developing resources to help communicate the collective return on investment seen by a society where all people and the planet thrive.