President Obama announced in January the award of $2.3 billion in Recovery Act Advanced Energy Manufacturing Tax Credits for clean energy manufacturing projects. These tax credits are focused on putting Americans back to work by building a robust domestic manufacturing capacity to supply clean and renewable energy projects with American-made parts and equipment, according to the White House Office of the Press Secretary. These credits are also an important step toward meeting the president’s goal of doubling the amount of renewable energy the country uses in the next three years with wind turbines and solar panels built right here in the USA.  

But the creation of green jobs has been slow in coming as a whole, let alone in the clean energy sector. In fact, roughly 85,000 jobs were reportedly lost in December of 2009 alone. So, how does any of this affect the AEC industry? Well, despite the green job revolution taking its sweet time, some makers of architectural and building products have been able to put initiatives into place and help move things along. Why? Because it’s essential for the future of their businesses.  

According to Dana Castle, principal and director of strategy for Function:, a marketing agency specializing in the architectural and construction industries, green isn’t an option for manufacturers anymore. To effectively compete in the market, Castle says that many building product manufacturers must renew their focus on sustainability, energy efficiency and green through corporate initiatives, messaging and operations. “Sustainability is at the forefront of conversation as they work to develop and manufacture new products,” Castle says.            

She adds that some manufacturers have introduced programs to encourage employees, customers and the community to better manage their environmental footprint. “And as they introduce new green initiatives and continue to make their operations more environmentally efficient, she says, “we have found that building product manufacturers are capitalizing on this in their sales and marketing messages -- to show their dedication and understanding of industry needs and requirements.”  

Why, Where and How?

In 2008, EFT Research’s “Green Manufacturing: Adoption & Implementation Report” revealed that the corporate mindset around environmental initiatives is indeed changing, and the need to invest in innovative products and new technologies is growing. For example, 95 percent of respondents agreed that green manufacturing will continue to expand, encouraged by a variety of programs including:

Investing in recycling and reuse programs (65 percent)
Water-reduction programs (58 percent)
Continuous improvement (54 percent)
Energy management (50 percent)

Closed-Loop Recycling in Floors and Ceilings 

Initiatives to improve a manufacturing process may also impact product development. Several building product manufacturers, for example, have found that recycling has affected all facets of the company, the product itself and the environment.

CARPET: InterfaceFLOR’s Mission Zero promise of no environmental impact by 2020 is continuing to make progress throughout its modular carpet tile manufacturing facilities, according to Steve Arbaugh, vice president of brand marketing for Interface. Since 1996, energy consumption is down 44 percent, net greenhouse gas (GHG) emissions are down 71 percent, water intake is down 72 percent, and recycled and/or bio-based raw materials now make up 24 percent of all materials used.

“Manufacturing facilities and processes lie at the forefront of our environmental progress,” says John Wells, president of Interface Americas Inc. “From raw materials sourcing through production, delivery and eventual take-back of the final product, all decisions are viewed through the lens of sustainability.”

Manufacturing innovation made significant strides with the company’s Cool Blue backing line. This flexible-inputs line uses reclaimed carpet backing to make new backing with as much as 51 percent post-consumer material. The facility is powered by methane gas harnessed from the local landfill in a landmark partnership with the City of LaGrange, Ga.

Manufacturing innovation made significant strides with the company’s Cool Blue backing line. This flexible-inputs line uses reclaimed carpet backing to make new backing with as much as 51 percent post-consumer material. The facility is powered by methane gas harnessed from the local landfill in a landmark partnership with the City of LaGrange, Ga.

CEILINGS: Armstrong uses waste streams from other industries in its manufacturing to reduce the environmental footprint of its products. This increases the recycled content in its acoustical ceilings up to 82 percent and in its metal suspension systems up to 63 percent. Both pre-consumer and post-consumer waste streams help to reduce the use of virgin materials.

Furthermore, the company also practices extended producer responsibility by supplying a closed-loop recycling process. The Armstrong Ceiling Recycling Program enables building owners to ship old ceilings from renovation projects to an Armstrong ceiling plant instead of to a landfill. Since it began the program in 1999, Armstrong has recycled more than 80 million square feet of old ceiling tiles.

Anita Snader, environmental sustainability manager for Armstrong Ceilings and Walls, notes that the company continually analyzes the lifecycle impacts of its acoustical ceiling to improve the environmental attributes of its products.

“Armstrong Ceilings is proud of its environmental heritage and its growing portfolio of products and programs developed in support of sustainable design and the built environment,” Snader says. “It is our goal in all areas of the company, including manufacturing, to continually reduce our environmental footprint.”

Buildings: LEED-Certified Manufacturing Facilities

According to the U.S. Green Building Council, there are more than 1,600 industrial buildings currently registered with LEED, and many industrial/manufacturing facilities are already certified, including suppliers of green building products. 

For example, the Owens Corning plant in Gresham, Ore., which produces PINK extruded-foam insulation, earned a LEED Gold rating. The certification process was a good experience for the company, according to Mike Friderichs, blowing agent conversion leader. “Our commitment to meet LEED certification standards forced us to consider things we don’t normally consider,” Friderichs says. “Every aspect of construction and operation came under that scrutiny. It took us to the next level of sustainable construction. As we went through the process and changed our plans, we realized the changes were all good common-sense things with a payback. We will use these ideas elsewhere going forward.”

The plant in Gresham was also the first extruded-foam facility in the Pacific Northwest to start operations with new Owens Corning technology that eliminates the need for HCFCs (hydrochlorofluorocarbons).  

According to Gale Tedhams, sustainability director at Owens Corning, this “changed thinking” is welcome and helping the company live its commitment to sustainability.