MAIZEWOOD

In research

Photo courtesy: Bob Reding

MAIZEWOOD. The unique building material manufactured from cornstalks was developed through the pioneering work of Dr. Orland Russel Sweeney of Iowa State University. Maizewood production created economic benefit from one of Iowa's most plentiful agricultural waste products. Distribution of maizewood was handled through CARR, RYDER, AND ADAMS COMPANY.

Dubuque was the first city in the United States to utilize cornstalks for the manufacture of insulating boards. Built in Dubuque in the 1920s, the MAIZEWOOD INSULATION COMPANY was operated by the Maizewood Products Corporation of Chicago, Illinois. This company was controlled in 1929 by the National Cornstalk Processes Inc. which had obtained a controlling interest in the Dubuque Company. National Cornstalk Processes had on its board executives of International Harvester, Deere and Company and former Governor Frank O. Lowden of Illinois and George N. Peek who had been leaders in farm relief activities. (1) In 1929 the Wall St. Journal reported that the company employing between 100 and 115 men would have an annual output of an estimated 30 million feet of insulation board requiring about 17,500 tons of corn stalks. (2)

The product using Iowa and Illinois cornstalks was chosen to provide roof and wall insulation at the Chicago Century of Progress Exposition in 1930. The total order amounted to over three-quarters of a million square feet of one-half inch insulation. The roof of the Travel and Transportation building alone used an estimated five acres of inch-thick insulation. (3)

In 1937 a new research laboratory was added to the company's other buildings. The purpose of the laboratory was to develop new uses for the by-products and waste products of Iowa farms, including cornstalks, fibers, and raw materials. The company's present lab was not equipped for such work. (4) In December, 1941 a two-story office addition was added to the north end of the plant. (5)

Stacks of cornstalks ready for processing. Photo courtesy: Library of Congress

Initially farmers living in the area near Dubuque were offered $9.00 per ton for loose, unbaled stalks or $10.00 a ton if the stalks were baled and delivered to the factory. Once the stalks were delivered, they were shredded and then cooked for two hours under steam pressure of one hundred pounds. The material was then washed and cleaned before again being cut to reduce the length of the plant fibers.

After cutting, the material was again washed and then mixed with rosin to give the finished product more water repellency. Two more refining machines were used to remove coarse pieces and leave the material in a silky condition ready for the final manufacturing step.

Workman checks the cutting table. Photo courtesy: Library of Congress

Sheets of maizewood coming from the dryer.Photo courtesy: Library of Congress

The damp material was spread over a screen on the board-forming machine. Excess water was allowed to drain off before the material was put through a press. By now formed into one continuous sheet, the maizewood was cut into twenty-foot lengths before moving into a drier. The boards were then baked at a temperature of 320 degrees, rough edges were removed, and the boards cut into various lengths. (6)

A disastrous fire occurred December, 1931 at the plant located at Railroad and Salina with a loss estimated at $92,000. (7) Company officials quickly stated that there were no grounds for criticism of the fire department which responded quickly with the general alarm sounding within two minutes of the first alarm. (8) The fire, however, led to a master fire alarm box being installed in the plant in March, 1932. Branch fire alarm boxes located throughout the plant allowed anyone discovering a fire to sound an alarm without needing to travel long distances. Gate valves were installed in the water mains to the plant to insure an adequate supply of water. (9)

In 1943 Maizewood Park was under development on Charter Street. Since the construction of the office addition to the plant in 1941, company officials had to look out their windows at switch tracks, rubbish heaps, and sand dunes. A beautification program was begun on property close to the plant. Sand dunes were flattened and covered with earth into which plantings were made. Switch tracks were moved. The project became so popular that the ground once part of the Rafferty Slough reclamation project years before was added to the beautification program. Employees of the company constructed a small white church which was located in a grove of cottonwood trees. Plans called for opening the park to the general public in 1944. (10)

Production of maizewood was brought to an end with the development of the mechanical corn picker which left the stalks unusable. In place of cornstalks, wood fiber was gathered by the Celotex Company which purchased the Maizewood Company. Production of ceiling tiles and panels expanded. (11)

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Source:

1. "Dubuque Product Used on World's Fair Buildings," Telegraph-Herald and Times-Journal, September 8, 1930, p. 2

2. "Wall St. Journal Tells of Progress at Maizewood Plant," Telegraph-Herald and Times-Journal, January 7, 1929, p. 11

3. "Dubuque Product Used..."

4. "Maizewood Firm to Build New Research Laboratory," Telegraph-Herald, July 14, 1937, p. 1

5. "New Park in Making," Telegraph-Herald, September 12, 1943, p. 5

6. "Wall St. Journal..."

7. 'Dubuque Sawmill Industry Died in Spectacular Fire," Telegraph-Herald, September 22, 1958, p. 4

8. "Praises Work of Firemen at Factory Fire," Telegraph-Herald and Times-Journal, December 15, 1931, p. 13

9. "Master Fire Alarm Box to Be Installed at Maizewood Plant," Telegraph-Herald and Times-Journal, March 20, 1932, p. 12

10. "New Park in Making..."

11. "The Celotex Company," Telegraph Herald, July 7, 1980, p. 30