The Ultimate Guide on PVC Material + 7 Key Pros & Cons to Consider

Polyvinyl chloride (aka PVC or vinyl) has been a foundational pillar of plastics manufacturing for nearly a century. From hospital tubing to highway billboards, PVC quietly underpins modern life—and yet most people hardly give this ubiquitous plastic a second thought. 

At Renegade, we’ve spent years dismantling the old assumptions surrounding legacy materials so we can build a better, more sustainable product. That means understanding PVC inside and out: its key properties, its production process, and the stark realities embedded in its use and disposal.

This article cuts through the marketing haze and engineering jargon to reveal what makes PVC material unique, where it thrives, and where it stumbles. First we’ll map out its two major categories—rigid PVC and flexible PVC. 

Then we’ll focus on flexible vinyl by outlining eight common applications and exposing seven critical pros and cons. Along the way, you’ll see subtle (and not‑so‑subtle) signposts pointing toward a transition away from flexible vinyl to polypropylene‑based solutions that outlast, outperform, and out‑green traditional PVC.

What is PVC? The 2 Main Types You Must Know (& How They’re Made)

PVC was first synthesized by accident when glass flasks filled with vinyl chloride gas were left in the sunlight and a white solid appeared. However, it was not until 1913 when a German inventor patented PVC and began to develop commercial applications. In 1926, discoveries by Waldo Semon led to the creation of more flexible PVC, which set the stage for its current market proliferation. 

PVC has two major pathways of industrial formation. 

1. One begins with the reaction of ethylene and chlorine.
2. The other begins with the reaction of hydrogen chloride with ethylene. 

Both form ethylene dichloride, which is then subjected to high heat and pressure (thermal cracking) to produce vinyl chloride monomers. 

That monomer is polymerized to create PVC resin, a white powder prized for its chemical resistance and low production cost. Manufacturers tweak its functionality by blending in various additives—heat stabilizers, impact modifiers, processing aids, pigments, and plasticizers—before extruding, calendaring, or molding it into sheets, pipes, or film.

The resulting material appears in two primary physical forms:

1. Rigid PVC – Most commonly made from PVC that contains little or no plasticizer. Think window frames, PVC pipes, credit cards, and drain fittings. It’s inherently strong, corrosion‑resistant, and dimensionally stable at high temperatures compared with other commodity plastics. Its low-cost has led it to be ubiquitous in our modern lives; however, products still often contain lead-based stabilizers and the products are difficult to recycle.
2. Flexible PVC – Add phthalate or citrate plasticizers, and the polymer chain loosens into a supple, rubber‑like fabric. This is the stuff used to make many common products such as inflatable rafts, cable insulation, blood bags, and waterproof tarpaulins. Plasticized PVC stakes its reputation on being bendable and durable—at the expense of compatibility with standard recycling and environmental safety.

8 Common Uses of Flexible PVC Materials

Flexible PVC’s adaptability has made it a go-to material across dozens of industries. From industrial covers to inflatable products, here are eight of the most common and commercially significant uses—each revealing where PVC shines, and where its limitations begin to show.

1. Tarpaulins and Covers: Truck side curtains, construction sheeting, and industrial drop cloths rely on laminated PVC fabric for waterproof protection and abrasion resistant strength. The material’s meltable nature lets manufacturers hot‑air‑weld massive panels with minimal stitching.
2. Signage and Advertising: Flexible banner fabric coated with PVC delivers bright ink adhesion and weather resistant durability, making it the default choice for highway billboards and retail backdrops. For fast‑changing campaigns, its low cost can outweigh long‑term waste concerns for some consumers.
3. Architectural Membranes: Stadium roofs and tension structures deploy PVC sheets reinforced with polyester yarn. The composite handles wind loads, sun exposure, and temperature extremes while staying lighter than glass or metal.
4. Protective Clothing: Chemical splash suits, raincoats, and aprons leverage chemical resistance and seam‑weldability. While these garments block some aggressive chemicals, they are heavy and impractical to recycle.
5. Inflatables: From kids’ bouncy castles to emergency shelters, inflatable products count on airtight fabric that can flex repeatedly without cracking. Flexible PVC dominates here despite concerns over exposure to plasticizers.
6. Transport Industry: In trucks and railcars, coated fabric curtainsider systems resist road grime, UV exposure, and tearing. PVC earns points for mechanical impact resistance, but weight penalties cut into fuel efficiency.
7. Geotextiles: Landfill caps and pond liners can use PVC for properties like impermeability and weldable seams to contain leachate and prevent groundwater contamination. Still, PVC presents potential issues with leaching of dioxins and phthalates into soil and groundwater. .
8. Sports and Leisure: Gym flooring, yoga mats, and inflatable paddleboards showcase PVC’s versatility. Yet athletes increasingly demand phthalate‑free, lighter‑weight alternatives—exactly where Renegade’s polypropylene‑based fabric thrives.

Why Choose Renegade Tarps Over Ones Made Out of PVC Material?

Renegade Plastics engineered a polypropylene‑based coated fabric that outmuscles legacy PVC products without the baggage. Our flexible fabrics deliver equal or better chemical resistance, higher tear strength per area, and a 30‑50% lighter footprint compared to the flexible PVC counterparts—slashing transportation emissions before the product even reaches the jobsite. 

Renegade tarps can also be used with traditional hot air welding equipment or impulse welding equipment so expensive manufacturing changes are not needed. Unfortunately, our products don’t work with ultrasonic welding equipment, but no one’s perfect.

Best of all, our material is able to be recycled into high‑quality polypropylene post‑consumer resin, closing the loop where PVC post-consumer products typically head straight for the landfill.

Polyvinyl Chloride Material Has a Few Pros, but Many Cons…

Despite undeniable versatility, polyvinyl chloride exists in a gray area where performance perks are hampered by health and environmental red flags. Below we weigh the scales.

1. Heavy

Compared with advanced polypropylene‑based flexible fabrics, PVC carries a bulk penalty of 30–60 %. Extra weight means higher shipping costs, more fuel burned, and tougher manual handling for installers. When fabric covers scale into the thousands of square feet, every kilogram shaved pays dividends in labor and fuel economy. At the end of a project, PVC needs to be disposed of in a landfill. Due to its heavy weight, landfill disposal fees can add up quickly.

2. Toxic

The core building block of PVC—a vinyl chloride monomer also called chloroethene—is a known human carcinogen. While modern safeguards limit occupational exposure, downstream incineration can release chlorine‑laden dioxins into communities. For the consumer, plasticizer leaching and exposure to lead or cadmium are the main concerns. Phthalates, which are known endocrine disruptors, are one of the most common additives to vinyl fabrics. Because of this, the concentration of eight specific phthalates are regulated in children’s products, but they are still allowed and the usage of dozens more phthalates are unregulated. Renegade’s polypropylene‑based fabric never uses plasticizers, vinyl chloride, phthalates, or lead based stabilizers, keeping consumers, workers, and our planet safe

3. Unrecyclable

Rigid or flexible, at the end of its life cycle most PVC ends up in landfill because separating embedded additives and reinforcing scrim makes mechanical recycling economically unattractive. Energy‑intensive chemical routes exist, but they produce potentially harmful, and unusable byproducts. By contrast, Renegade’s mono-material architecture is designed for recycling in existing PP streams.

4. Versatile 

Give credit where it’s due: PVC adapts to nearly any usage—temporary drinking water tanks,   printable fabrics for billboards, or outdoor apparel—thanks to various additives and a range of plasticizing and extrusion techniques. Tough but also flexible, PVC meets the challenges of large weather-resistant covers, marine-grade upholstery, and even inflatable attractions and flotation devices.That manufacturing agility has created a broad range of flexible fabrics that have captured markets for finished products, even as more advanced options emerge.

5. Low Cost 

Feedstock abundance and mature supply chains make PVC one of the world’s most low cost engineered plastics. For budget‑squeezed projects, the upfront savings can be compelling—although lifecycle math often tells a different story once disposal, maintenance, and transportation fuel are factored in.

The Top 5 PVC Material FAQs

Still have questions about PVC material? Below are answers to some of the most frequently asked questions about its safety, recyclability, cleaning methods, popularity among manufacturers, and emerging alternatives.

1. Is PVC safe for human health? Within regulated limits, finished PVC products are considered safe; however, concerns remain around vinyl chloride exposure during production and plasticizer migration over time.
2. Can PVC be recycled? Limited specialty programs offer mechanical recycling, but post-consumer material is widely viewed as unrecyclable at scale because of mixed additives and scrim layers.
3. How can I clean PVC? A mild detergent applied with a soft sponge is best. Make sure to thoroughly dry PVC after washing to avoid mildew formation in cracks. If disinfection is required, then bleach, isopropyl alcohol, or hydrogen peroxide solutions may be suitable. Make sure to dilute bleach solutions 10:1 and follow any manufacturer guidelines.
4. Why is PVC so popular among manufacturers? Mature tooling, low cost, and the ability to tailor performance through various additives keep manufacturers invested.
5. Are there lighter weight alternatives to flexible PVC? Yes. Polypropylene‑based coated fabric from Renegade delivers equal strength at half the weight, slashing fuel costs and installation effort. We have a wide variety of offerings that can replace many vinyl products from tarps to mattress covers to pond liners.

Rising Pressure to Move Beyond PVC: Manufacturers at the Crossroads

As the world changes, are you prepared to change with it? 

Here’s a few recent regulatory, consumer, and worker safety trends for manufacturers to pay attention to when it comes to flexible polyvinyl chloride products.

• Phthalates

Phthalates are a group of synthetic chemicals used in a wide variety of consumer products. They are used in polyvinyl chloride as a plasticizer to create a flexible and durable laminate. Prenatal and early childhood exposure can cause neurological and reproductive disorders in humans. 

1. Since 1999, the European Union (EU) has banned the use of six phthalates – diisononyl phthalate (DINP),di(2-ethylhexyl) phthalate (DEHP), di-n-butyl phthalate (DBP), di-”isodecyl” phthalate (DIDP), dioctyl phthalate (DNOP), and benzyl butyl phthalate (BBP) – in children’s toys.
2. The EU commission has expanded this ban to include additional phthalates and limitations of the concentration of phthalates in other consumer products such as electronics, medical devices, and food packaging.
3. The US has designated seven phthalates as hazardous substances under the Comprehensive Environmental Response, Compensation, and Liability Act (CERCLA), three as hazardous pollutants under the Clean Air Act, and in 2019 six phthalates were listed as “high-priority” substances for risk evaluation under the Toxic Substances Control Act (TSCA). 
4. Individual US states are also implementing their own phthalate regulations to limit phthalate exposure through products, water, and air. 
5. Litigation has started picking up with cases growing against manufacturers by consumer advocacy groups who make claims inconsistent with having phthalates in their products. 

There is a growing awareness of the health risks posed by phthalates and consumers are demanding action from state and federal agencies. The best way to get ahead of these regulatory and consumer trends is to transition to a flexible coated plastic fabric without plasticizers, which is Renegade Plastics’ specialty.

• Extended Producer Responsibility

Extended Producer Responsibility (EPR) laws shift the responsibility for end-of-life management of products from consumers and local governments to producers. The goals of these programs are often to reduce waste and encourage producers to design a more sustainable product. 

1. The first EPR law was enacted in the EU in 1994 and it focused on regulating the types of packaging that could be used, waste management of packaging, and waste prevention.
2. In the US there are 145 EPR laws in 34 states across 20 product categories. These are growing every year.
3. Numerous states have EPR laws for consumer items for which flexible PVC may be used such as mattresses, carpeting, boat wrap, textiles, and products containing PFAS.
4. Many EPR programs have a reduced financial burden for manufacturers whose products are easy to recycle or made of recycled content – two problematic areas for PVC. And two areas where Renegade’s polypropylene-based fabrics excel.

The best way to avoid costly end-of-life disposal obligations through EPR laws, is to make a voluntary commitment to materials, like our products, that are designed for circularity.

• Workplace Safety

The Occupational Health and Safety Administration (OSHA) has set limits for exposure to vinyl chloride since it is a suspected carcinogen. However, concerns for worker safety are not just limited to vinyl polymerization. Fabrication with flexible PVC is known to realize a variety of volatile organic compounds (VOCs) that can cause headaches, nausea, and other health effects. Employers want a healthy and competent workforce, and exposure to VOCs from flexible vinyl fabrics is not the way to do this.

• PFAS, PVC, and other toxic chemicals

In general, consumers are beginning to question the chemicals in their products. They demand safe plastics that meet the expectations of modern life without the toxic baggage. From PFAS to vinyl chloride to lead, manufacturers need to plan ahead for these demands to ensure their long-term success. 

Polyvinyl chloride drives billions in annual sales yet sits on regulatory watch lists. Some engineers defend polyvinyl chloride for its flame retardancy, others criticize polyvinyl chloride for toxic additives. Stakeholders tracking EPR laws or PFAS/phthalate/lead regulations will watch polyvinyl chloride closely; transitioning away from polyvinyl chloride now can pre‑empt future compliance headaches. When procurement teams tally carbon footprints, toxicity, worker safety, and circularity scores, polyvinyl chloride seldom lands on top. That’s why leading brands treat polyvinyl chloride phase‑out as both a moral imperative and a market opportunity. 

In short, ignoring polyvinyl chloride alternatives is no longer an option for businesses that want to stay ahead.

Where Do We Go From Here? The Future of PVC Material

Forward-thinking manufacturers know what’s coming: PVC is steadily losing its social license to operate. Regulatory pressure is building from all directions. Europe’s Green Deal includes PVC in its roadmap for phasedown, targeting chlorine-based compounds and pushing hard on circular economy mandates.

In the U.S., California’s Truth in Recycling Law narrows what counts as “recyclable,” effectively calling out PVC products that can’t meet real-world recovery standards. Meanwhile, new EPR (Extended Producer Responsibility) programs are flipping the script—shifting end-of-life accountability from consumers and governments onto the brands themselves.

If your product is difficult or dangerous to recycle, it’s not just an environmental liability—it’s a financial one. That’s especially true for flexible PVC, which rarely fits cleanly into modern recycling streams.

At the same time, consumer expectations are evolving faster than most supply chains can adapt. End users want safe, clean, toxin-free materials. Workers want fewer VOCs and safer jobs. Parents don’t want phthalates in their kids’ toys. States like Maine, Washington, and New York are enacting new chemical disclosure laws, and litigation is starting to catch up with brands that ignore the warnings.

In this new reality, betting on PVC is like investing in lead paint or asbestos insulation. Choosing Renegade isn’t just a materials upgrade—it’s an insurance policy for your brand’s future. Our fabrics eliminate vinyl chloride monomer, skip the plasticizers, and still outperform on strength and durability. With Renegade, you’re not just following compliance trends—you’re leading them.