Over the past 75 years, plastics have infiltrated daily life largely without question. Production skyrocketed from an estimated 2 million tons in 1950 to more than 470 million tons in 2019.¹ And without intervention, plastic use is projected to surge in the decades to come.

Plastic’s ubiquity isn’t accidental. It has revolutionized modern life through life-saving medical devices, lightweight materials that improve fuel efficiency, and countless innovations. Despite their benefits, plastics are also one of our most pressing environmental and health challenges. They are made from fossil fuels and contribute to climate change. The chemicals used to make plastics have been linked to cancer, reproductive dysfunction, and other health harms. They pollute the air, water, soil, and our bodies, and create massive amounts of waste at the end of their—often too short—useful lives.

The good news? Change is happening. Across sectors and industries, sustainability professionals are reducing plastic use, municipalities are implementing plastic reduction policies, and innovative alternatives are reaching the market. We have unprecedented opportunities to drive meaningful change in reducing plastics’ impacts. Here we’ll provide facts you need to understand plastics’ impact and pathways forward.

• What are plastics?
• How are plastic products made?
• How do plastics drive fossil fuel demand?
• How much plastic is made and thrown away?
• Why aren’t plastics as cheap as they seem?
• What is plastic pollution?
• How does plastic pollution harm everyone?
  • Climate change
  • Microplastics
  • Toxic Chemicals
• Who is disproportionately harmed by plastics?
• What can you do to fight against plastic pollution?

Plastics are synthetic or semi-synthetic materials made of polymers and chemical additives. Modern synthetic plastics came on the scene about 100 years ago.² Almost all plastics (99%) are made from fossil fuels: oil, natural gas, or coal.³

Plastic production begins with fossil fuel extraction; these fossil fuels are then refined and processed into petrochemicals. Petrochemicals are used to create different types of plastics with specific properties. Manufacturers shape these plastics into everyday products, often adding other chemicals to make them stronger, more flexible, or colorful.

As the energy sector shifts to renewables, the fossil fuel industry has turned toward plastics as a way of maintaining demand for their planet-harming products.^4,5 The International Energy Agency has predicted that petrochemicals, which are used to make plastics, will soon become the largest driver of global oil demand.⁶

Global plastic production was over 470 million tons in 2019.¹ This is more than the weight of all the humans alive today.⁸ And annual production is projected to double by 2050.¹ Industry is on track to create more plastics in the next 25 years than have been produced in the history of the world so far.^1,a

When they think of plastics, people often think of packaging—and, indeed, packaging makes up a significant 31% of all plastics’ use. But the building and construction sector is the second-biggest contributor, responsible for 17% of global plastics production. From PVC pipes to nylon carpet and vinyl siding, tens of millions of tons of plastics are used in construction each year.¹⁰ Other major uses include transportation, textiles, consumer and institutional products, and electrical/electronic equipment and devices.

Plastics last a long time and do not biodegrade, which translates to a lot of plastic waste.¹¹ Humankind generated about 390 million tons of plastic waste in 2019,¹ and this amount is projected to almost triple by 2060, reaching over 1.1 billion tons per year.⁹ The vast majority of plastic waste is landfilled, incinerated, or mismanaged (disposed of in uncontrolled dump sites, burned in open uncontrolled fires, or leaked to the environment where it builds up in ecosystems on land and in waterways).^1,12 For example, international estimates project that by 2060, there could be a staggering 543 million tons of plastic accumulated in aquatic environments, including 160 million tons in the ocean.⁹

While many plastic materials appear inexpensive, the price tag excludes substantial societal costs of harm to human health and the environment.¹³

Annually, production of plastics causes an estimated $592 billion in health harms globally.^14,b A small subset of plastic-related chemicals generates an estimated $249 billion in medical and associated social costs every year in the U.S. alone.¹⁵ Plastic pollution is estimated to result in $100 billion of environmental damage every year.¹³ And these are conservative estimates.^c Reducing plastics use can lead to major health and economic benefits.

The costs of climate change, too, are immense. Global warming increases the frequency of extreme weather events, each causing billions in damage. The U.S. faced 27 separate billion-dollar weather and climate disasters in 2024 alone—nearly matching the record-setting 28 events in 2023. These disasters resulted in over $182 billion in damages that year.¹⁶ Plastic production contributes to these mounting costs.

Government subsidies hide the real cost of plastics, with annual global subsidies totaling $7 trillion for fossil fuels and on the order of $30 billion for plastic production in the top 15 producing countries.^17,18 A similar pattern exists at the local level. The Environmental Integrity Project reviewed 50 plastic plants built or expanded in the U.S. since 2012 and found that 32 of these plants received almost $9 billion in state and local tax breaks and taxpayer subsidies. Two-thirds of the more than 591,000 people living within three miles of the 50 new or expanded plants are people of color, revealing how environmental burdens often fall disproportionately on communities of color.¹⁹

These costs are paid by individuals and governments, not fossil fuel or plastic companies.¹⁴

The United Nations defines plastic pollution as “the negative effects and emissions resulting from the production and consumption of plastic materials and products across their entire life cycle.”¹³ Plastics generate pollution at every stage of their life, from fossil fuel extraction, through manufacturing, use, and disposal. This pollution—including greenhouse gases, microplastics, and toxic chemicals—harms everyone.

Widespread pollution generated across the plastic life cycle is harming people and Earth’s ecosystems.^12,20 Sometimes this pollution is readily apparent: smoke plumes or smells from a factory or plastic bottles in the gutter. Whether we can see or smell it or not, plastic pollution affects all of us—through greenhouse gas emissions; through the microplastic particles and toxic chemicals that make their way into our bodies from air, water, and food; and through impacts on the health of people and our planet. For example:

Climate change

Plastics contribute to climate change at every stage of their life cycle. Greenhouse gases are released during fossil fuel extraction, refining, and transportation. Plastic manufacturing processes emit additional climate pollutants. Even after use, plastic products continue damaging the climate as they degrade or burn in incinerators.²¹ Plastic production alone is responsible for over 5% of global greenhouse gas emissions and continues to grow.²²

Microplastics

While plastics don’t biodegrade, they do break down into small and tiny particles known as micro- and nanoplastics. These particles range from about the size of an orange seed to the width of a strand of DNA, and they are everywhere.²³ We are exposed to them through the food we eat, the water we drink, and the air we breathe. Microplastics have been found throughout human bodies, including our blood, kidneys, hearts, brains, and more, and there is evidence they build up over time.^24–27 Project TENDR, an alliance of experts on toxic chemicals and brain development, notes that, “[b]abies today are born with their brains and bodies already contaminated with plastics. Micro- and nano-plastic particles have been found in the placenta and newborns’ first stool, with exposures continuing through breastmilk and infant formula.”²⁸ Scientists are only just starting to learn how microplastics harm the health of children and adults, but research suggests they contribute to a range of adverse outcomes, such as cancer and infertility.²⁹

Toxic Chemicals

In addition to plastics themselves being a health concern as described above, plastics also use and release toxic chemicals throughout their life cycle. These chemicals are used throughout plastics production—extraction and refining of fossil fuels and production of chemicals, plastics, and products. In addition to “regular” releases of toxic chemicals that occur during production, each life cycle step and transportation of chemicals for each process also creates risk of fires, explosions, spills, and leaks.³¹ More than 16,000 different chemicals may be used to make, or are present in, plastics. Over 25% of these are known to be hazardous to human health or the environment, and most others lack information on their safety. This includes thousands of chemicals that are intentionally added to plastics to impart particular properties, such as making them more flexible, durable, or colorful.³² Chemicals used to create plastics pollute our air, water, soil, and bodies and have been linked to cancer, reproductive issues, children’s developmental harm, asthma, obesity, and many more health impacts.^14,33–36

Human Health Impacts

Workers, communities, and users of plastic products face direct exposure to these harmful substances. Additionally, chemical wastes from plastic production and most plastic products themselves are landfilled or incinerated, burdening communities with additional pollution.^1,14,34,37 Even recycling can release microplastics and toxic chemicals that affect human health.^38,39

Environmental Impacts

Beyond local contamination, many plastic chemicals as well as microplastics spread globally through air and water, disrupting ecosystems and contaminating environments worldwide.^1,32,36 Landfilling and incineration of plastic waste further burdens the environment with persistent pollution, while recycling processes can also release environmental contaminants.^14,32,38,39

While we are all harmed by plastic pollution, some of us are harmed more than others.

Children are especially vulnerable to chemical exposures. Beginning in the womb and continuing into adolescence, their cells and bodies are in a dynamic state of growth.⁴⁰ Chemical exposures have many damaging effects. They can interrupt hormone systems and inhibit healthy brain development. Scientists suspect chemical exposures have contributed to the increased rates of childhood cancers like leukemia and neurodevelopmental disorders like ADHD present today.^28,40,41 Exposure to toxic chemicals early in life can continue to harm health years later through effects such as reduced fertility and increased risk of obesity, asthma, and cancer.⁴¹

Communities near polluting facilities (chemical plants, landfills, incinerators, etc.) are directly affected by noise, odors, chemical emissions, and heavy duty diesel emissions.^42–44 Such “fenceline” communities are disproportionately communities of color, Indigenous communities, and low-wealth communities.^14,42,45 Often, industrial facilities are concentrated in “sacrifice zones” such as Louisiana’s Cancer Alley. This 85-mile stretch of communities along the Mississippi River between New Orleans and Baton Rouge is home to about 200 fossil fuel and petrochemical facilities. Residents of the area suffer from elevated rates and risks of reproductive, maternal, and newborn health harms; cancer; and respiratory ailments such as asthma.⁴⁶ Hear directly from Cancer Alley residents in this video from Human Rights Watch.

Plastic chemicals and microplastics travel through air and ocean currents, concentrating in the Arctic and disproportionately affecting the land, water, and traditional foods of Arctic Indigenous communities.^36,47 Climate change is also greater in Arctic regions which are warming almost four times faster than the planet as a whole. The health of these communities is threatened by the toxic impacts of the fossil fuel and plastics industry in addition to climate-induced threats to food security and community displacement.³⁶

From the vinyl flooring under our feet to the polyester in our clothing, plastics surround us in ways we’re only beginning to fully understand. The evidence is clear: these ubiquitous materials are driving climate change, contaminating our bodies with chemicals and microplastics, and releasing toxic chemicals that disproportionately harm children, communities of color, Indigenous communities, and low-wealth communities. The hidden costs reveal the true price of our plastic dependency. 

Here are four concrete steps you can take right now to meaningfully reduce plastic use while protecting people and the environment:

• Minimize new material use and reuse existing products when possible
• Choose healthier materials when new products are necessary
• Choose long-lived, timeless materials that remain in place for their full service life
• Evaluate recycling claims critically, as recycling often perpetuates rather than reduces plastics’ harmful life cycle impacts

The same innovation that created this challenge can solve it. As sustainability professionals, we have the knowledge, networks, and influence to accelerate the transition already underway.

So, let’s consider what would need to happen for plastic building products to be considered truly sustainable. Can the plastics industry do better? What are the key opportunities today to do so, and what global policy tools could promote these opportunities? These are among the key questions HBN explored in the development of a pair of case studies for the international Organization for Economic Co-operation and Development (OECD) as part of the Inter-Organization Programme for the Sound Management of Chemicals (IOMC).

Before we jump into the case study findings, first, let’s define plastics. For the purposes of this article, we define plastics to be any polymeric material, fossil fuel based or bio-based. The case studies focused on durable plastic goods, using building materials as an example.

The case studies explored both plastic flooring and plastic insulation with the goal of increasing awareness of environmental and human health impacts of plastic product production at each stage of the lifecycle and proposing policy interventions that can help move the industry toward more sustainable plastics products in general.

There are three reasons for this: technical, economic, and behavioral. The inherent qualities of PVC and its cousin, CPVC, make it among the most technologically challenging plastics to recycle. Like most plastics, PVC is made with fossil fuel feedstocks. Unlike other plastics, PVC/vinyl also contains substantial amounts of chlorine, upwards of 40%. This is the C in PVC, and this chlorine content adds an additional layer of negative impacts to the earth and its people, social inequity, and an impediment to recycling that cannot be overcome. Recyclers consider it a contaminant to other plastic feedstock streams.1 It mucks up the machines and the already perilous economics of plastics recycling.

There is an emerging global consensus on this point, albeit euphemistically stated. The Ellen MacArthur New Plastics Economy Project consists of representatives from the world’s largest plastic makers and users, along with governments, academics, and NGOs. In 2017 it reached the conclusion that PVC was an “uncommon” plastic that was unlikely to be recycled and should be avoided in favor of other more recyclable packaging materials.2 “Uncommon” in the diplomatic parlance of international multistakeholder initiatives means unrecyclable. The project also took note of the many toxic emissions associated with PVC production.

That’s not surprising since after 30 years of hollow promises and pilot projects doomed to fail, virtually no post-consumer PVC is recycled.3 Conversely, leading brands with forward-looking materials policies such such as Nike, Apple, and Google have prioritized PVC phase outs.4

But in the building industry, PVC rages on. Virgin vinyl LVT flooring is the fastest growing product in the flooring sector. So much so that in 2017 sustainability leader Interface introduced a new product line of virgin vinyl LVT, despite forecasting just one year before that by 2020 the company would “source 95 percent of its materials from recycled or biobased resources.”5

The current flooring market demands the impossible – aesthetic qualities and durability at a price unmatchable by non-vinyl floor coverings. A price that is unmatchable because at every stage of vinyl production, the societal costs of its poisonous environmental health consequences are externalized, subsidized, paid for by the people who live in communities that have become virtual poster children for environmental injustice and oppression. Places like Mossville, LA; Freeport, TX; and the Xinjiang Province in China, home to the oppressed Uighur population. As we detail in our exhaustive Chlorine and Building Materials report, the unique chlorine component of PVC plastic contributes to a range of toxic pollution problems starting with the fact that chlorine production relies upon either mercury-, asbestos-, or PFAS-based processes. This is in addition to the onerous environmental health burdens of petrochemical processing that burden all plastics.

It is true that all plastics contribute to environmental injustices. Virtually all plastics are made from fossil fuel feedstocks, and all plastics share abysmally low recovery and cycling rates. Still, independent experts agree that some plastics are worse than others, and PVC is among the worst.6 Additionally, most uses of PVC have readily available alternatives or solutions that are within reach. Certainly there are non-PVC alternatives for flooring. What can’t be beat is the cost – that is, the low purchase price at the point of sale, subsidized by the sacrifices we ignore in the communities where the plastics are manufactured and the waste is dealt with. And BIPOC communities bear the disproportionate burden of it all. Acknowledging and addressing this tradeoff is at the root of the behavioral change that stands between us and a just and healthy circular economy.

In his influential book How To Be An Antiracist, Dr. Ibram X. Kendi argues that if we recognize we live in a society with many racial inequities – and acknowledge that since no racial group is inferior or superior to another, the cause of these inequities are policies and practices – then to be anti-racist is to challenge those policies and practices where we can and create new ones that create equity and justice for all.

Imagine if as part of our commitment to equity in our sustainability efforts, we recognized, acknowledged, and did what we could to address the racial inequities associated with PVC production, and committed right now to stop using PVC unless it was absolutely essential. The plastics industry would howl and point out inconsistencies, question priorities, highlight unintended consequences. We would all feel a tinge of whataboutism – what about carbon, or this other injustice, or that shortcoming of the alternatives. But it is clear that widespread incrementalism is failing us on so many fronts, none more than the environmental injustices that are hardwired into our supply chains.

In fact, there are many examples of companies and building projects that have prioritized PVC-free alternatives based upon principles of equity and justice. We need more leaders in the field to join those who are abandoning vinyl in product types that have superior options. Our CEO Gina Ciganik used a non-PVC flooring in 2015 at The Rose, her last development project prior to joining HBN.