In a report released by StopWaste and the Healthy Building Network, we take an in-depth look at the health implications, supply chain considerations, and potential to scale up recycling of the world’s most common plastic: polyethylene (aka PE). [1] This report, Post-Consumer Polyethylene in Building Products, is the latest installment in our Optimizing Recycling series.

Polyethylene is a material widely used in product packaging, beverage containers, and myriad consumer products. High Density Polyethylene (HDPE), Low Density Polyethylene (LDPE), and Linear Low Density Polyethylene (LLDPE) are all readily recyclable in California. Polyethylene plastic scrap bottles and plastic bags usually have minimal contents of concern and are easily processed into feedstock for new products, including building materials. Despite the great potential for recovery of PE, sizeable barriers stand in the way of a lot more recycling.

The explosive growth in virgin ethylene production on the U.S. Gulf Coast, driven by cheap energy, has meant that most post-consumer scrap PE is either landfilled, incinerated, or sent overseas for processing. [2]

The announcement came after lengthy negotiations led by the Mind The Store Campaign, a grassroots effort supported by the Healthy Building Network’s (HBN) cutting-edge research on building products.  Mind The Store is challenging the country’s largest retailers to restrict 100 hazardous chemicals in the products they sell. Also today, the Mind The Store campaign released a report identifying phthalates and other chemical hazards detected in vinyl flooring products.

Aaron Freiwald is an attorney representing the cancer victims in a class action lawsuit against Rohm & Haas, which bought the suspect facility from the Morton Chemical Company in 1999. According to Freiwald, “By the time we are done with this case, the association between vinyl chloride and brain cancer is going to be much stronger. They are going to have to revise the way current textbooks discuss cancer risks associated with vinyl chloride.”

One critical factor in the case is the clear connection between the vinyl chloride and the cancers.  It can be difficult to prove a specific chemical causes a specific cancer because so often people have multiple exposures to carcinogens.  But, Lake McCollum is an isolated community.  There are no other significant industrial sources of chemical contamination to which the 14 victims have been exposed.  According to the International Agency for Research on Cancer (IARC), vinyl chloride is carcinogenic to humans and has been associated with brain cancer.

Phthalates are used as plasticizers to soften polyvinyl chloride plastic, also known as PVC or vinyl, including a wide range of building products such as vinyl flooring, wallcovering and upholstery.

Phthalate plasticizers are not chemically bound to PVC. They have been found to leach, migrate or evaporate into indoor air and atmosphere, foodstuff, IV solutions and other materials, etc. Consumer products containing phthalates can result in human exposure through direct contact and use, indirectly through leaching into other products, or general environmental contamination. Humans are exposed through ingestion, inhalation, and dermal exposure during their whole lifetime, starting in the womb. Phthalates come in many different formulas. Most haven’t been tested or examined at all for human health impacts. The Consumer Product Safety Commission has noted that one phthalate formula common to certain building materials — DINP [1] — is a mixture of up to 100 chemical variants, of which only five have been minimally studied [2]. Others have been found to pose a risk of serious negative health impacts at very low doses.

Phthalates have been shown to have negative effects on human health including interference with the natural functioning of the hormone system, and reproductive and genital defects. Phthalates may lower sperm count and are associated with the risk factors for testicular cancer, as well as early onset of puberty and premature birth.

In June 2005, HBN discussed recent research findings that the cumulative impact of different phthalates leads to an exponential increase in associated harm, and documented levels of phthalates found in humans at levels higher than levels shown to cause adverse health effects. A 2007 study concluded that the exposure of children to phthalates exceeds that in adults, warning, “Current human biomonitoring data prove that the tolerable intake of children is exceeded to a considerable degree, in some instances up to 20-fold” [3].

Phthalates have been found in high quantities in studies of household dust. Other studies have documented links between childhood asthma and phthalate exposure from vinyl flooring. Because phthalates are not a volatile organic compound (VOC), however, they are usually not accounted for by indoor air quality standards such as those used to certify green building materials.

The CSB Investigation Report is made all the more relevant to green building professionals in light of the USGBC’s finding that PVC flooring ranked absolute worst in both human health and environmental factors compared to the alternatives reviewed. The destroyed factory, owned by Formosa Plastics, had been a major supplier of vinyl resin for Armstrong floors.

The CSB is the industrial equivalent of the National Transportation Safety Board (NTSB), the agency that rushes investigators to the scene of plane crashes, train derailments and the like. [1] The CSB’s March 6, 2007 report found among other things that the cause of this accident, “inadvertently draining a reactor, is a serious hazard in the PVC manufacturing process.” [2] Indeed just 60 days before the fatal explosion, workers at the same facility accidentally released an undisclosed amount of vinyl chloride. The report also notes that 8,000 pounds of vinyl chloride were released by accident in June 2003 at the company’s Baton Rouge, LA facility. [3] A year after the explosion, in May 2005, another 2,500 pounds of vinyl chloride were accidentally released from the company’s Delaware City, DE location. [4] Each release was caused by the same problems which led to the catastrophe at the Illiopolis facility in April 2004. Other PVC factories owned by Formosa have also suffered catastrophic explosions in the recent past. [5]