The practice of upcycling, prevalent in sectors such as construction, not only revitalizes discarded items, adding value and function, but also helps transform them into valuable resources. Adopting the spirit of the circular economy by utilizing agricultural waste, such as corn stalks, rice straw, and sugarcane bagasse, for construction materials marks a fundamental shift toward sustainable practices, promoting a closed-loop system that minimizes waste and optimizes resource efficiency.
CornWall® , developed by Stone Cycling, stands as a pioneering innovation in this area. Inspired by the imperative shift towards a bio-based economy, it incorporates a transformative solution that addresses the pressing concerns of the construction industry's environmental impact. ArchDaily interviewed Ward Massa, a visionary at Stone Cycling, about the material, a wall finish made from plant biomass, primarily obtained from the kernels of locally sourced corn. This organic waste is widely available and is typically destined for fermentation, burning as biomass, or simply becoming organic waste.
"Most current projects use conventional products that require a lot of energy and raw materials in the manufacturing process. Especially for retail and hospitality interiors, renovations are needed every five years. This means that wall cladding materials are often demolished and discarded. CornWall can be used for similar applications, but it's a sustainable product that can be 100% recycled or reused. This means there is no waste at the end of its life. Even if the product cannot be reused, it is still biodegradable, leaving no trace.".
Dried corn cobs undergo a meticulous shredding process, transforming them into primary biomass. This biomass, composed of over 99.5% plant-based material, forms the basis of this sustainable material. A touch of color can be added to this mixture, equivalent to incorporating less than 0.5% biodegradable pigments.
Photo: CornWall.
The transformation is carried out through high-pressure pressing and heat infusion, requiring temperatures of up to 150 degrees Celsius. Notably, the energy powering this critical phase of production comes exclusively from solar panels adorning the roof of the production facility. After pressing and precision cutting, a bio-based, waterproof coating is applied, enhancing the material's durability and functionality. Packaged in lightweight, thin panels, approximately 4 mm thick and weighing about 5 kg per m², CornWall® optimizes transport efficiency compared to bulkier materials such as ceramic or HPL.
In an industry facing numerous challenges related to waste production and environmental impact, the product emerges as a beacon of hope. Ward Massa emphasizes: “An important aspect of circular construction is its dismantling, ensuring that everything can be separated and reused at the end of its lifespan. That’s what we do with CornWall.” The intricate process of utilizing abundant resources, incorporating renewable energy, and creating a versatile and environmentally friendly material underscores the product’s pivotal role in reshaping sustainable construction practices.
The concept of being climate-positive means a product's ability to sequester more carbon dioxide during its growth or creation phase than it emits during production, promoting a net reduction of carbon in the atmosphere. Furthermore, the emphasis on zero waste and complete recyclability or biodegradability ensures a sustainable life cycle, unlike conventional materials such as HPL or ceramic tiles that require significant raw material and energy consumption during production, ultimately contributing to high levels of waste.
Looking ahead, there is immense potential beyond its current applications in interior walls and furniture coverings. Ward sheds light on the project's future roadmap, stating, "To maintain the biodegradable properties, we will now limit ourselves to interior applications. In the future, we will make larger panels and perhaps flooring materials.".
Photo: CornWall.
Now available for delivery in Europe and the United States, the product also offers technical documentation accessible through its download center. While the material price is in line with that of high-quality ceramic tiles, processing and end-of-life costs are significantly lower, positioning it as an economical and environmentally conscious choice.
CornWall® can be customized in terms of color, texture, and size, satisfying bespoke projects and tailored sustainable solutions. It represents a milestone in the evolution of sustainable building materials. Its innovative characteristics, commitment to circularity, and expansion potential not only redefine the construction landscape but also exemplify a conscious approach to architecture and design.
Photo: CornWall.
The collaborations with Circular Matters and Studio Nina van Bart also represent a commitment to innovation and sustainable construction, demonstrating a joint effort to redefine the future of bio-based building materials and propel CornWall® into new realms of possibility. On the path to a more sustainable future, this initiative is a testament to the innovation, sustainability, and immense potential of bio-based materials in shaping the architecture of the future.
