I don't think your going to find any evidence that will make you feel better about using expanded PVC. The only thing I'll add is that Celtec 550 is the only expanded PVC product that I know of rated suitable for food contact. As a bonus, it is one of the lightest expanded PVC products. But just because it's suitable for food contact does not mean it's "safe" when exposed to some of the temperatures that us herpers use. Polyethlene and polypropylene are very safe but I would not put a torch to either and purposely inhale the fumes.
Some types of cage heaters get extremely hot, even though they might only be heating a small area to 90*. If these heaters are in close proximity to the plastic they might cause offgassing. Understand that this might be a problem as well for the plastics that are considered safe. When the USDA rates a plastic suitable for a cutting board, for example, they assume it won't be heated to 130* during use.
On that note, room heat along with radiant heat panels would probably be the safest option if the concern is what these materials do when exposed to high temperatures. RHP's don't get very hot and won't have to do much if the room is already warm.
There are other plastics that have been tested more thoroughly, like the already mentioned polypropylene and polyethylene. Both of those tend to be very heavy, very expensive and in many cases more likely to warp. I looked at many products of both types and was very surprised at how much they varied in quality. I would hate to order either sight unseen in hopes that I could build cages or racks from it.
What are your main reasons for using plastic? Weight savings, durability, or what?
I like plastics but many people dive into them thinking they are the right material. Many people have built cages from plastic they ordered only to find that they ended up with a cage that is more expensive, heavier and more likely to warp than a cage built from plywood.
There is no perfect cage building material or technique. Everyone of them comes with its own set of tradeoffs. Make sure you choose yours carefully.
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Current snakes:
0.0.1 Gonyosoma oxycephala - Java locale (green)
1.2 Gonyosoma oxycephala - Jave local (green)
2.2 Gonyosoma janseni - Seleyar locale (all black)
1.2 Gonyosoma janseni - Celebes locale (Black & Tan)