Construction Informer

Corn Board Manufacturing Inc. (CBMI) will use a corn-based structural composite technology developed by the University of Illinois at Urbana-Champaign (Illinois). The new product CBMI plans to produce is called CornBoard™, according to a press release issued by the University of Illinois.

Not to be confused with a famous edible product called cornbread, CornBoard™ is a version of wood composite board that uses up the corn husks and stalks (stover) left behind after the corn is harvested. The structural composite is made by mixing the fibrous corn component with a polymer matrix, laminating the mixture, and applying heat and pressure.

In contrast to traditional particle board, plywood, or medium-density fiberboard (MDF), CornBoard™ developed at CBMI will use a biomass material that is often left in the field. For every acre of corn grown, (over 86 million acres are grown annually in the U.S), more than 4,000 pounds of corn stover is left in the field. CBMI and the University of Illinois report that “using the material in new and innovative products is an efficient and environmentally conscious means of stewardship.”

The partners highlight CornBoard™ as a green technology because it traps CO2. Typically, when biomass is left to decompose in the field, the CO2 previously captured and consumed by the growing plant is released back into the atmosphere, according to the press release. Conversely, when the corn stover is made into CornBoard™, the CO2 is “trapped” in the material. Sequestering CO2 in CornBoard™ alleviates the contribution of the decomposing biomass towards an increase of CO2 in the atmosphere.

The product is also said to provide an alternative to wood products, thereby reducing the demand on a less renewable resource. According to CBMI, two acres of leftover corn stover biomass would produce enough CornBoard™ to supply the roof decking, sub-flooring and outer wall sheathing of a typical two-story house. CBMI uses a non-toxic resin binder in CornBoard™ production claimed to be a safer and more environmentally conscious choice than traditional formaldehyde-base binder.

The product is made in varying densities, allowing for a variety of applications. It is not limited to just being a wood composite board replacement, but is also being developed into a variety of products including home and lawn furniture, kitchen cabinets, door cores, and a full line of longboards.

CBMI is introducing the Zea Home™ Outdoor Furniture Collection, a line of outdoor furniture made from 100% CornBoard™. The first item to be released is an Adirondack chair- an easily assembled piece requiring no fasteners or adhesives.

Illinois inventors, Dr. Nancy Sottos, Dr. Scott White and Dr. Thomas Mackin developed the technology that makes CornBoard™ possible.

It does seem a little strange to me how we keep trying to take food crops and use them for something other than food, especially in a world where two-thirds of the inhabitants go to sleep hungry each night. Granted these plant parts wouldn’t normally be eaten by people but they just might leave something behind during decomposition that makes next year’s crop more abundant. I guess only time will tell if building materials made from corn bring more value to the world than food made from corn. In the meantime, incorporating corn into a building will no doubt take the buy-in of more than a few standards committees, and a slew of code officials.