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CGPP Report 2004/24

AT A GLANCE
The aim of this project was to
investigate the possibility of reducing
volatile organic compound (VOC)
emissions by switching from the use of
high-solvent-based blast primers in the
treatment of structural steel to a waterbased primer. The latter would have
similar drying characteristics to its
solvent-based counterpart. However, it
would have a less detrimental effect on
the environment. The project also
involved operational improvements in
the companys paint shop: this has
reduced VOC emissions from the plant
by approximately 15%.

COMPANY SUCCEEDS IN REDUCING WASTE

PAINT AND VOC EMISSIONS.
AIMS OF THIS PROJECT
The aim of this project was to reduce the
level of Volatile Organic Compound (VOC)
emissions from the companys
Portarlington-based paint plant in the most
efficient and effective way possible. VOCs
are solvents, present in paints and which
can have adverse effects on the

SIAC BUTLERS STEEL LTD

Printed on recycled paper using water based inks

The assets of Butlers Steel were

acquired by SIAC in 1996: SIAC Butlers
Steel is now part of the SIAC
Construction Group, whose head office
is located in Clondalkin, Dublin.
SIAC Butlers Steel is a major supplier of
structural steel to the construction
industry. It designs, fabricates and erects
the structural steel elements of buildings
as diverse as hotels, shopping centres,
office blocks, leisure complexes and
manufacturing facilities. Recent projects
include the National Aquatic Centre, a
national distribution centre for a
multinational retail chain and office
blocks at Georges Quay in Dublin. The
company also undertakes projects
outside Ireland: it is currently involved in
erecting the steel structures of buildings
in Scotland and in the Isle of Man.
The company employs approximately
100 people at its state-of-the-art plant
in Portarlington, Co Laois: the plant is
strategically located in the Midlands in
order to service the companys nationwide customer base.

environment and on human health.

Fig 1. The existing shot-blasting and

priming line

All structural steel that passes through the

Portarlington plant (i.e. up to 500 tonnes

PROJECT DESCRIPTION

per week) is shot-blasted at the start of

the fabrication process. It is then treated

The original objective of this project was

with a coat of solvent-based primer in

to substantially reduce the plants level

order to prevent corrosion reforming

of VOC emissions. The company

during the fabrication process. As this is an

intended to achieve this by upgrading

in-line process (i.e. the steel is shot-blasted

the blast primer coating system so that

in line between the initial cutting and

it could operate with a water-based

preparation operation, and the welding

primer rather than a solvent-based

and fabrication section, and without any

primer. Moreover, it was intended to

possibility of buffering the steel), the

reduce paint usage and wastage

drying time to touch dry must be 4.5

through operational improvements; to

minutes or less.

convert the steel pre-heating thermal

supply to run on more energy-efficient
natural gas, and to raise awareness of
environmental issues amongst the
plants workforce.

BETTER BUSINESS IN A BETTER IRELAND

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Fig 2. Steel preheating line

Fig 3. Automatic priming line

ACHIEVEMENTS
While it was not possible to carry out the requisite plant and
equipment overhaul within the 12-month CGPP project
timeframe, some initial exploratory trials of water-based
blast primer took place in November 2003 (with the main
trials scheduled for February 2004). SIAC Butlers Steel held
discussions with three paint manufacturers: these discussions
focused on developing and supplying a high-performance
water-based blast primer. In addition, the equipment
required in order to operate water-based coating

Fig 4. Shot-blasted and primed steel

applications was identified.

Operational improvements focused on:
The suitability of a state-of-the-art spraying system for two-

Raising awareness of the importance of minimising

pack paints (i.e. where the two components, base coat and

over-spraying; improving mixing procedures;

hardener, are not mixed until immediately before

maximising the usage of paint from each paint

application) was investigated. Traditionally, the two

container, and fostering good housekeeping practice

components are batch-mixed in bulk prior to use. There is

among the paint shop workforce.

potential for the creation of significant quantities of waste

paint if a consignment is not used within the pot life of the

Raising queries at both the planning stage and costing

mix. The proposed new equipment was designed to reduce

stage as to why certain parts of a structural member

the release of solvents associated with the wasted paint. It

might need to be primed; why a lower solvent paint

would also reduce the amount of paint solids, which are

might not be used; or why there was a need for

created by the generation of unnecessary waste.

priming at all!

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Tabling environmental issues for review at all bi-

The coatings industry is becoming increasingly aware that

monthly health, safety and environmental

high-performance water-based paints are being demanded

management meetings.

by the market. This demand is effectively being led by endusers, who are influenced by impending environmental

These operational improvements have led to a 15%

legislation.

reduction in solvent emissions: this corresponds to about 10

tonnes of solvent per year.

MORE INFORMATION
For more information on this project contact:
Gerry C. McCarthy
Coatings Manager
SIAC Butlers Steel Ltd
Lea Road
Portarlington
Co Laois

Tel: 0502-23305
Fax: 0502-23207
Fig 5. Finished steel, ready for erection

Email: gc.mccarthy@siacbutlers.ie
Website: www.siac.ie

SECONDARY AIMS
Additional goals of this project included reducing gas
consumption and energy costs; improving the knowledge
base of employees working in areas where the levels of
VOC emissions are directly influenced by those employees
work practices.

LESSONS
While the one-year timeframe was too short a period to
make significant changes at the plant, SIAC Butlers Steel
believes that bringing this project to completion is the most
effective way for it to meet its objective of achieving a
substantial reduction in VOC emissions.

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CLEANER GREENER
PRODUCTION IS
the application of integrated preventive environmental
strategies to processes, products, and services to increase
overall efficiency and reduce risks to humans and the
environment.
Production processes: conserving raw materials and
energy, eliminating toxic raw materials, and reducing the
quantity and toxicity of all emissions and wastes
Products: reducing negative impacts along the life cycle
of a product, from raw materials extraction to its
ultimate disposal.
Services: incorporating environmental concerns into
designing and delivering services.

CLEANER GREENER
PRODUCTION REQUIRES
new attitudes, better environmental management, and
evaluating available technology options. We need to take
good environmental practice to the stage where it is an
inherent part of any business operation.

HOW IS CLEANER GREENER

PRODUCTION DIFFERENT?
Much of the current thinking on environmental protection
focuses on what to do with wastes and emissions after they
have been created. The goal of cleaner, greener production
is to avoid generating pollution in the first place.
This means:

Better efficiency
Better business
Better environmental protection
Lower costs
Less waste
Less emissions
Less resource consumption

WHY IS THE CLEANER

GREENER PRODUCTION
PROGRAMME BEING RUN?

The long-term goal is to ensure that cleaner, greener production

becomes the established norm in Ireland. The programme seeks to
promote environmentally friendly business through increased
resource productivity, waste reduction, recovery of materials,
improved efficiency in a product value chain, energy management,
and a change of culture within organisations.
The programme aims are focussed on avoiding and preventing
adverse environmental impact rather than treating or cleaning up
afterwards. This approach brings better economic and
environmental efficiency.

PROGRAMME MANAGERS:
The Clean Technology Centre (CTC) at Cork Institute of
Technology was appointed to manage the programme in
association with OSullivan Public Relations Ltd, and Energy
Transport Actions Ltd, (ENTRAC).
The CTC was established in 1991 and is now nationally and
internationally regarded as a centre of excellence in cleaner
production, environmental management and eco-innovation across
a range of industrial sectors.

WHERE CAN I GET

FURTHER INFORMATION?
This case study report is one of 29 reports
available from the organisations that
participated in the first phase of the Cleaner
Greener Production Programme. A summary
of all the projects and CD containing all the reports
are also available. More information on the Programme
is available from the Environmental Protection Agency
Ms. Helen Walsh,
CGPP,
Environmental Protection Agency,
Richview, Clonskeagh Road, Dublin 14, Ireland.
Tel. 01 2680100
Website

Fax. 01 2680199

www.epa.ie

select link to cleaner production.

Email. ertdi@epa.ie
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The Irish Government, through the National Development

Plan 2000 - 2006, has allocated funds to a programme for
Environmental Research, Technological Development and
Innovation (ERTDI).

The Department of the Environment and Local Government asked

the Environmental Protection Agency (EPA) to run the CGPP as
part of the ERTDI programme. With the programme continuing to
2006 about 60 businesses will be supported to implement cleaner
greener production and to demonstrate their achievements to the
rest of Ireland.