Everything to Know About Vinyl Chloride Exposure

Vinyl chloride, an indispensable yet hazardous chemical, is one of the building blocks of modern life. The tragedy of the train derailment in East Palestine, Ohio, has vividly underscored its dual nature. The train, laden with 50 cars, of which 10 carried hazardous materials, was severely damaged and leaking vinyl chloride gas. To eliminate this risk, crews had to ignite and burn the vinyl chloride—a decision that will indelibly impact the town and its residents.

In this article, we take a closer look at vinyl chloride—what it is, its applications, the effects of exposure, and why ensuring proper handling is critical for the safety of workers and the public.

What Is Vinyl Chloride & What Is It Used For?

Scientifically speaking, vinyl chloride is a clear and mostly odorless gas that takes on a sweet scent in dangerous quantities. Through pressurization, vinyl chloride becomes a liquid, which is how it’s typically stored and transported.

From a manufacturing point of view, vinyl chloride is among the top 20 most-produced petrochemicals in global industry. This manufactured substance is predominantly used to create polyvinyl chloride (PVC) plastic products. Virtually every residential or commercial property you’ve ever visited has PVC pipes installed.

The versatility of vinyl chloride extends beyond pipes. It is used in the manufacture of automotive parts, furniture, packaging materials, wall coverings, wire coatings, vehicle upholstery, and plastic kitchenware. It is also employed as an intermediate in producing other chlorinated compounds and as an element in mixed-monomer plastics. Historically, vinyl chloride functioned as a solvent, propellant, refrigerant, and was even evaluated as a potential anesthetic.

What Happens If You Are Exposed to Vinyl Chloride?

As vinyl chloride becomes a gas in most natural environments, exposure typically occurs by inhalation. Alarmingly, such exposure poses a greater risk than natural gas or ammonia. The East Palestine train derailment demonstrated the dangers of a controlled vinyl chloride burn, releasing phosgene and hydrogen chloride into the air. Phosgene, a notorious WWI weapon, can induce vomiting and hinder breathing. Though less toxic, hydrogen chloride can irritate the eyes and skin.

The main victims of vinyl chloride exposure are workers involved in its production, use, transportation, storage, and disposal, but as we’ve seen, residents can also become exposed through chemical spills or other accidents. Vinyl chloride exposure can occur through leaks, improper use of personal protective equipment (PPE), and sample collections at manufacturing facilities or industrial factories. Nearby communities can be exposed to vinyl chloride by breathing contaminated air or using water contaminated with vinyl chloride for showering, cooking, or laundry. Families of workers who handle vinyl chloride can face increased risk of repeated exposure if workers come home with it liquefied into their clothing.

Vinyl Chloride Exposure Symptoms

As a colorless gas, vinyl chloride exudes a mild, sweet odor at high levels. Acute exposure can irritate the eyes, mucous membranes, and respiratory tract. It can also cause frostbite or skin and eye irritation when escaping compressed gas or if it contacts a person’s skin as a liquid.

Vinyl chloride exposure mainly affects the central nervous system. Symptoms often include:

• Dizziness
• Ataxia (lack of coordination/balance)
• Inebriation
• Fatigue
• Numbness
• Tingling of the extremities
• Visual disturbances

In severe cases, exposure to vinyl chloride can also lead to coma and death.

Chronic exposure to vinyl chloride can inflict permanent liver damage, leading to liver cancer, neurologic or behavioral symptoms, and changes to the skin and bones of the hand. It can increase the risk of a rare form of liver cancer called hepatic angiosarcoma, as well as primary liver cancer (hepatocellular carcinoma), brain and lung cancers, lymphoma, and leukemia. Workers who have had prolonged exposure or exposure at high levels face higher risks, according to studies done on PVC pipe makers.

What to Do If You Are Exposed to Vinyl Chloride

Sadly, there is no direct treatment for vinyl chloride exposure. Medical intervention is limited to supportive care, such as focusing on stabilizing respiratory and cardiovascular functions, preventing further absorption, and managing symptoms as they arise. Because vinyl chloride is both toxic and carcinogenic, even brief exposure can pose serious health risks. Immediate action is critical.

If you or someone nearby is exposed to vinyl chloride—whether in the form of a gas leak, chemical spill, or industrial accident—take the following steps right away:

• Move to Fresh Air Immediately: If vinyl chloride is inhaled, the most important first step is to get away from the contaminated area and into fresh air as quickly as possible. Avoid breathing deeply while evacuating.
• Flush Eyes Thoroughly: If the chemical contacts the eyes, flush them gently but continuously with clean water for at least 15 minutes. If wearing contact lenses, remove and discard them.
• Submerge Skin in Warm Water: If the skin has come into contact with liquid vinyl chloride, immediately immerse the affected areas in warm (not hot) water. Do not rub or scrub the skin.
• Remove Contaminated Clothing: Carefully take off any clothing that may have vinyl chloride on it, and seal it in a plastic bag to prevent others from being exposed. Avoid pulling clothing over the head; cut it off if necessary.
• Seek Emergency Medical Attention: Even if symptoms seem minor, prompt medical evaluation is essential. Tell medical personnel you may have been exposed to vinyl chloride so they can take appropriate precautions.
• Monitor for Symptoms: After exposure, watch for symptoms such as dizziness, drowsiness, headache, difficulty breathing, or numbness in the limbs. Delayed effects are possible and should not be ignored.
• Report the Incident: If exposed at work, notify your employer, OSHA, or the appropriate environmental or public health authorities. Exposure to hazardous chemicals must be formally documented.

When it comes to toxic chemical exposure, time matters. Fast, informed action can reduce long-term harm and ensure proper medical treatment.

Vinyl Chloride Production, Handling, & Transportation

At room temperature, vinyl chloride is a gas. For easier handling, the chemical is typically stored as a liquid in pressurized tanks and is transported via pipeline, rail, or truck. Handling vinyl chloride requires personal protective equipment (PPE) at all points of its manufacture, storage, transportation, and use. The storage equipment must be corrosion-resistant to prevent slow leaks.

Any reforms or improvements to how vinyl chloride is handled should, in theory, be fairly quick to implement. That’s because in the U.S., only four companies produce vinyl chloride:

• Westlake Chemical (35% of supply)
• AGC Chemicals (25% of supply)
• Olin Corp (20% of supply)
• Kaneka Corporation (19% of supply)

The large-scale production implies that any accident would potentially affect a large number of workers and have extensive impacts.

How Employers Can—and Must—Protect Workers from Vinyl Chloride Exposure

Workers should never have to choose between earning a living and their lives. When it comes to toxic chemicals like vinyl chloride, employers bear a legal and moral responsibility to ensure that safety is never compromised. Vinyl chloride is a known human carcinogen, and exposure—especially in industrial settings—can lead to serious, life-altering illnesses. Preventing that exposure is not just a best practice. It’s the law.

Employers in industries where vinyl chloride is manufactured, used, or transported must take proactive, comprehensive steps to safeguard their workforce. This includes everyone from plant operators to maintenance crews, emergency responders, and even subcontractors working on-site.

Essential employer responsibilities for vinyl chloride safety include:

• Implement Ventilation Systems: Industrial areas where vinyl chloride is present must be equipped with high-efficiency ventilation to prevent the buildup of toxic gases. Proper airflow can significantly reduce inhalation risks.
• Monitor Air Quality: Employers should use real-time air monitoring systems and conduct routine tests to detect vinyl chloride levels. The results should be documented and made available to workers.
• Provide Personal Protective Equipment (PPE): Workers must be equipped with appropriate PPE, including respirators, gloves, chemical-resistant clothing, and eye protection. Employers are responsible for supplying, maintaining, and training workers in the correct use of this equipment.
• Develop and Enforce Safety Protocols: Clear, site-specific safety procedures for handling vinyl chloride must be established and strictly followed. This includes protocols for leaks, spills, storage, and transportation.
• Conduct Regular Safety Training: All employees should receive ongoing training about the dangers of vinyl chloride, how to recognize symptoms of exposure, and what to do in case of an emergency. Training must be updated any time there are changes to equipment, processes, or regulations.
• Maintain Proper Chemical Labeling and Storage: Containers with vinyl chloride must be clearly labeled and securely stored to prevent accidental exposure. Storage areas should be isolated and comply with OSHA and EPA regulations.
• Create an Emergency Response Plan: Employers must have a fully developed, practiced emergency plan in case of a vinyl chloride leak or spill. This includes evacuation procedures, decontamination processes, and medical response coordination.
• Report and Investigate Incidents Promptly: Any exposure, leak, or safety concern must be documented, reported to authorities, and thoroughly investigated to prevent recurrence.

When employers cut corners, the consequences can be devastating, not only for workers but for entire communities. Protecting workers from vinyl chloride exposure requires vigilance, investment, and a genuine commitment to safety. Anything less is unacceptable.

At the end of the day, workers handling vinyl chloride face the highest risk of exposure. Given its importance and profitability, manufacturers should spare no expense in providing workers with top-tier PPE and storage/handling equipment to prevent exposure. For workers already facing long-term harm or shorter lifetimes due to exposure, companies like Westlake and AGC Chemicals must spare no expense in providing for their medical care and other losses.

It is not just a matter of doing the right thing but acknowledging the sacrifices these workers make so we can enjoy the benefits of this incredibly versatile chemical product.