PVC Highlights From PPXXII

PVC at PPXXII – Day 3 Highlights

18/09/2025

Discover all PVC highlights from the Plastic Pipes XXII conference in Warsaw, Poland.

The Plastic Pipes Conference XXII (PPXXII), held in Warsaw in September 2025, brought together the global plastic pipe industry to showcase the latest research, case studies, and innovations.

For the PVC sector, the three days of technical sessions confirmed the material’s role as a future-ready solution for drinking water, wastewater, gas, hydrogen and other sustainable gases, and industrial infrastructure.

From 100+ year design lifetimes and large-diameter PVC-U pipes, to advanced microstructural research on PVC-O, cutting-edge recycling technologies, regulatory readiness and hydrogen compatibility, the conference underlined how PVC pipes continue to adapt and lead in a changing world.

PVC4Pipes played an active role at PPXXII. Project Leader Vincent Stone and Consultant Tobias Johnsen represented the platform with three presentations and by chairing one of the technical sessions, while partners Molecor and Hultec joined as Cooperate Sponsors.

PVC4Pipes and Uni-Bell PVC Pipe Association co-sponsored the iPad Award for best PVC paper, which went to Daniel Voces of Molecor for his groundbreaking study on microstructure-performance relationships for PVC-O pipes.

It was also announced in Warsaw that PPXXIII will take place in Houston, Texas, USA, 25–27 September 2027.

Below, we present the full set of PVC highlights from PPXXII, organised by day.

Best PVC Paper: Microstructural Insights for PVC-O Pipes

Daniel Voces (Molecor) presented award-winning research on the microstructure of oriented PVC (PVC-O) pipes, offering a deeper understanding of how molecular orientation enhances mechanical performance.

By aligning molecules during production, PVC-O achieves:

Superior strength-to-weight ratios.
Higher impact resistance.
Greater pressure capacity compared to conventional PVC-U.

The study demonstrated that optimising orientation parameters can further improve durability and long-term reliability. Using advanced analytical techniques, the research confirmed how microstructural characterisation can guide future enhancements, ensuring PVC-O continues to lead in performance and sustainability.

PVC-O pipes are already widely recognised as one of the most efficient solutions for water transport, combining light weight with low energy use in pumping and reduced raw material demand. This paper reaffirmed their role at the forefront of sustainable pipeline solutions.

EU Drinking Water Directive: Implications for PVC Pipes

Cristina Costa (Shin-Etsu/Cires) presented Understanding the Impact of the New Drinking Water Directive (DWD), a paper examining how the legislation sets new requirements for all materials in contact with drinking water.

Key changes include:

An incomplete first version of the EU Positive List (EUPL).
Extremely stringent migration limits of 0.1 µg/L.
New rules on non-intentionally added substances (NIAS).
Many EUPL-listed substances will face expiry dates by 2028.

For PVC pipe systems, this means that manufacturers and suppliers must ensure all formulation substances are listed, renew approvals on time, and prepare notifications in IUCLID for substances with upcoming expiry dates.

PVC4Pipes has already published a guidance document to help the industry navigate these stricter requirements.

Super-Sized PVC-U Pipes for Infrastructure Projects

Chelsea Qin (Shanghai Jurry Plastics Machinery) presented the successful development of PVC-U pipes with an outside diameter of 1600 mm — among the largest in the world.

These super-sized PVC-U pipes create new possibilities for urban water supply, large-scale irrigation, and drainage networks. They combine the proven durability and light weight of PVC-U with the ability to compete directly with alternative materials in very large dimensions.

The presentation emphasised that these pipes deliver:

Ease of installation compared to heavier traditional materials.
Efficiency in production, with lower energy use.
A long service life, contributing to sustainability and cost-effectiveness.

With growing global demand for robust and eco-efficient infrastructure, super-sized PVC-U pipes represent a significant step forward.

Plastic Pipes in Sustainable Infrastructure – Dispelling Common Misconceptions

PVC pipes and other vinyl products have often been targeted by NGOs with allegations on safety and environmental impact. Such claims risk distorting market perception and may lead to misplaced preferences for alternatives like ductile iron, which in reality carry higher environmental footprints.

Tobias Johnsen of PVC4Pipes and VinylPlus® presented how the organisations are addressing these challenges with robust, evidence-based communication.

The presentation drew on the 2023 opinion from the European Chemicals Agency (ECHA), which confirmed that risks associated with PVC production are adequately controlled.

VinylPlus has since launched multilingual infographics and a comprehensive Q&A to tackle recurring NGO narratives, disseminating these resources throughout the value chain. Positive communication through the interactive map Vinyl & You and the Vinyl: Building a Sustainable Future on Three Pillars campaign was also highlighted.

Supported by targeted social media campaigns, the materials reinforce confidence in PVC’s safety and highlight its advantages: durability, cost-efficiency, eco-efficiency, and versatility in applications such as drinking water, sewage, irrigation, hydrogen, biogas, cable protection, and rainwater management.

This coordinated communication approach demonstrates how transparency and data can effectively counter misconceptions and serve as a model for other industries facing similar challenges.

New Environmental Datasets Strengthen Recycled PVC’s Case

Reliable environmental data on recycled PVC (r-PVC) has been scarce, limiting its use in Environmental Product Declarations (EPDs).

To address this, TEPPFA and VinylPlus co-funded new EU-representative Life Cycle Inventory (LCI) datasets for r-PVC flakes and micronised powder.

Jean-Pierre Taverne (TEPPFA) presented the results, which show:

r-PVC delivers 85–90% lower CO₂ emissions per kg compared with virgin PVC.
The datasets are ISO 14040/44-compliant, third-party reviewed, and aligned with EN 15804+A2 and forthcoming CPR requirements.
Flexibility allows users to reflect local conditions such as electricity mix.

These harmonised datasets give manufacturers and specifiers robust tools to demonstrate the climate benefits of recycled PVC in LCAs and EPDs.

Request download of datasets.

High-Filled PVC-O Pipes for Irrigation and Mid-Pressure Use

Ignacio Muñoz de Juan (Molecor) shared research on adapting PVC-O technology for markets that prefer thicker-walled pipes, such as irrigation networks.

By orienting a high-filler PVC-U formulation, usually reserved for non-pressure sewer pipes, Molecor produced pipes that outperformed standard PVC-U pressure pipes in fatigue and pressure tests.

Key advantages:

Robust handling for installation in less controlled environments.
Cost-competitive production with filler material.
Superior performance despite using a lower-grade formulation.

This shows how PVC-O can be successfully extended into new markets, reinforcing its role in sustainable water infrastructure.

Poland’s Sewer Networks Choose PVC

Piotr Fałkowski (Stowarzyszenie PRiK) documented the rapid rise of PVC in Poland’s gravity sewer systems.

From 1992 to 2005, PVC’s market share grew from 1.5% to over 80%, replacing traditional materials almost entirely.

Utilities embraced PVC due to its:

Durability and reliability in the field.
Ease of installation and lightweight handling.
Cost-efficiency compared to alternatives.
Environmental performance, with lower impacts over the lifecycle.

Poland’s experience shows how PVC can quickly become the preferred material when its benefits are communicated and proven in practice.

PVC vs Ductile Iron: Environmental Performance Compared

Lucy Croker (Vinidex) presented new Life Cycle Assessment (LCA) data comparing PVC pipes with ductile iron.

Findings included:

For DN100 pipes, ductile iron has five times the GWP of PVC-O.
PVC requires significantly less freshwater in production.
PVC’s light weight reduces transport and installation emissions.
In Australia, local production of PVC avoids shipping emissions linked to ductile iron imports.

The study confirms that PVC pipes outperform ductile iron across key sustainability indicators, strengthening the case for PVC in modern infrastructure.

Europe’s Plastic Pipe Industry Steps Up Recycling Commitment

Ludo Debever (TEPPFA) outlined how Europe’s plastic pipe industry is intensifying efforts to increase recycled content in line with the EU Green Deal.
Initiatives include:

Opening EN standards and product marks to recyclate.
Developing a CEN/TS for design for recycling.
Supporting research to qualify recycled materials for long-term applications.

National policies are emerging, such as Flanders’ requirement for 20% recycled content in non-pressure sewage pipes by 2027, with similar discussions underway in the Netherlands, Italy, and Germany.

Since pipes last 50–100+ years, recycled content targets will require additional feedstock beyond end-of-life pipes. TEPPFA members are mapping flows, monitoring EPR schemes, and exploring voluntary collection initiatives.

This coordinated effort shows the industry’s determination to advance circularity without compromising safety or performance.

PVC-U Pipes – Extrusion Conditions for a 100+ Year Lifetime

Joaquín Lahoz Castillo (CEISLAB) presented the second phase of his research into how extrusion parameters influence the long-term performance of PVC-U pipes.

Sponsored by PVC4Pipes, the study showed that optimising melt temperature, extrusion speed, and cooling conditions can deliver pipes with a design lifetime of over 100 years.

The findings provide valuable guidance for pipe producers and reinforce PVC-U’s status as a durable, safe, and cost-efficient material for modern infrastructure.

Part one of the study is available in the PPCA database.

Advanced Recycling Options for Legacy Additives

Vincent Stone (PVC4Pipes & VinylPlus) presented the latest advances in complementary recycling technologies for PVC.

Highlights included:

VinylPlus RecoChlor and similar processes recovering chlorine from waste-to-energy residues in a growing number of European plants.
A project with ARCUS Greencycling Technologies proving that pyrolysis of mixed waste with up to 10% PVC can yield oil suitable for petrochemical use.
Confirmation by Prof. Kevin Van Geem (Ghent University) that the oil can be processed in steam crackers after treatment.
Ongoing development of dissolution, gasification, and other advanced methods by VinylPlus partners.

This research forms part of a pre-study assessing legacy additives and mapping future pathways. The conclusion: both chlorine and hydrocarbons in PVC can be recovered, supporting the circular economy at scale.

Discover joint VinylPlus-ARCUS white paper.

Discover all recycling options for PVC.

A Solution for PVC Pipe Waste with Legacy Additives

Eric Romers (INEOS Inovyn) joined by video to present progress on selective dissolution as a solution for legacy additives.

His presentation showed how Vinyloop-D can safely recycle PVC pipe waste, producing REACH-compliant recyclate suitable for new pipe applications.

Key conclusions:

Vinyloop-D is targeting an industrial-scale unit by 2030.
The process ensures high-quality recyclate while removing legacy substances.
The PVC industry, under VinylPlus, is a leader in complementing mechanical recycling with advanced recycling.
Sorting and collection schemes remain essential to optimise recycling.
Clear regulatory frameworks are needed to support investment.

This presentation reinforced that innovation in recycling keeps PVC pipes and other products circular.

Advancing Climate Efficiency with No-Dig Renovation

On behalf of Claes Wiger (A-Plast), Tobias Johnsen (PVC4Pipes) presented research on trenchless or no-dig relining using bio-attributed PVC liners.

Benefits of this no-dig approach include:

35–55% lower CO₂ emissions compared to GRP and conventional PVC.
A 100+ year service life with full recyclability.
Styrene-free installation, safer for workers and home dwellers.
A scalable solution for modernising wastewater networks.
A green rating from Sweden’s Byggvarubedömningen.

In addition to the climate benefits, trenchless sewer repairs avoids social costs such as traffic disruption, noise, and dust, making it a more sustainable solution for communities.

PVC Pipes and the Hydrogen Transition

Sjoerd Jansma (Kiwa Technology) presented new research into the permeation of hydrogen through plastic pipes, focusing on PVC.

The study confirmed that PVC pipes show extremely low hydrogen permeation rates, making them a safe and compatible choice for hydrogen distribution networks.

In parallel, PVC4Pipes is funding and supporting validation work by Kiwa and partners on both existing PVC gas pipelines and new installations. This ensures that PVC’s proven track record in water and gas supply can extend to the next generation of energy infrastructure.

30 Years of Double Wall Corrugated PVC Piping Systems for Sewage Applications

Pablo Peinado (Molecor) presented a comprehensive review of three decades of double wall corrugated PVC piping systems for sewage applications.

The innovation of using lightweight PVC instead of traditional rigid materials revolutionised sewer networks and wastewater management.

Benefits highlighted include:

Chemical resistance, abrasion performance, and flexibility, leading to longer lifetimes.
Watertight joints that prevent leakage and ensure reliability.
High hydraulic capacity thanks to smooth internal surfaces and optimised design.
Lower weight and material use, reducing CO₂ emissions across the lifecycle.

The key to performance lies in the double wall structure: a smooth inner wall for flow efficiency combined with an outer corrugated surface that increases stiffness without adding excess material. Because PVC has low creep compared to other plastics, its stiffness remains stable over the long term.

Over 55,000 km of double wall corrugated PVC pipelines have already been installed worldwide, supported by a full system of fittings and manholes with elastomeric seals. This proven technology delivers over 50 years of service life, lower energy consumption in pumping, and strong environmental performance.

The presentation confirmed that corrugated PVC systems remain a benchmark solution for sewage infrastructure, combining engineering innovation with decades of reliable field performance.

Beyond Hoop: Axisymmetric Stress in PVC Pressure Pipe Joints

Guido Quesada (Hultec) presented advanced modelling and testing on PVC pressure pipe joints.

While hoop stress has traditionally been the main design criterion, joints are subject to complex axisymmetric stresses when exposed to real-world internal and external loads.

The research demonstrated how a more complete stress analysis gives a truer picture of joint performance, increasing confidence in long-term joint integrity.
This work underscores the importance of innovative joint design for ensuring leak-free, durable PVC pressure pipe systems.

PVC4Pipes is proud to have Hultec as a partner and Cooperate Sponsor of PPXXII.

PVC Highlights From PPXXII

PVC at PPXXII – Day 3 Highlights

PVC at PPXXII – Day 3 Highlights

Best PVC Paper: Microstructural Insights for PVC-O Pipes

EU Drinking Water Directive: Implications for PVC Pipes

Super-Sized PVC-U Pipes for Infrastructure Projects

Plastic Pipes in Sustainable Infrastructure – Dispelling Common Misconceptions

New Environmental Datasets Strengthen Recycled PVC’s Case

High-Filled PVC-O Pipes for Irrigation and Mid-Pressure Use

Poland’s Sewer Networks Choose PVC

PVC vs Ductile Iron: Environmental Performance Compared

Europe’s Plastic Pipe Industry Steps Up Recycling Commitment

PVC-U Pipes – Extrusion Conditions for a 100+ Year Lifetime

Advanced Recycling Options for Legacy Additives

A Solution for PVC Pipe Waste with Legacy Additives

Advancing Climate Efficiency with No-Dig Renovation

PVC Pipes and the Hydrogen Transition

30 Years of Double Wall Corrugated PVC Piping Systems for Sewage Applications

Beyond Hoop: Axisymmetric Stress in PVC Pressure Pipe Joints

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