Mechanical performance, structural optimization, and production of PVC axial hollow‐wall pipes through materials‐saving

Abstract A novel structural wall pipe, PVC axial hollow‐wall pipe (AHWP) has been developed to reduce carbon emissions during the “Full Life Cycle” of PVC pipelines by reducing material use in the pipe walls. The advantages and application prospects of AHWP are examined, followed by manufacturing prototypes using advanced production techniques. The material properties, internal and external pressure resistance, impact resistance, and buried load deformation of three types of AHWP were evaluated. Experimental and numerical simulations analyzed how the cross‐sectional structure on the mechanical performance of AHWP and proposed optimization pathways. Results indicate that the production process for AHWP closely resembles that of PVC solid‐wall pipes (SWP), allowing rapid large‐scale industrial production with appropriate adjustments. Material consumption for AHWP is only 60% to 70% of that for SWP. All three types of AHWP can withstand long‐term hydrostatic pressure of 0.6 MPa, meeting the basic mechanical performance requirements for low‐pressure and non‐pressure plastic drainage pipes, with circular‐hole AHWP demonstrating the best performance. The application of AHWP can diversify the drainage pipe market, and support the societal shift toward sustainable development, characterized by the conservation of resources and the reduction of greenhouse gas emissions. Highlights Validated new AHWP design for enhanced structural efficiency. Optimized AHWP for mechanical performance, cost, and energy. Developed and refined AHWP prototypes with manufacturing analyses. Established future structural improvement routes with testing. Demonstrated AHWP's potential in efficiency, materials, and applications.