Renewabuild Great Plains, co-founded by Ken Meyer of Complete Hemp Processing, is establishing the first U.S.-licensed manufacturing facility for structural hempcrete blocks. This development marks a step forward for industrial hemp in the construction sector, with a new factory in Rock Valley, Iowa, set to begin production.
The technology behind these unique structural hempcrete blocks originated with Just BioFiber in Alberta, Canada. It is now licensed and administered by another Canadian entity, Renewabuild Field to Form, which has refined the original block design. Unlike traditional hempcrete construction methods, such as spray-applied or cast-in-place applications, these blocks feature an internal frame that provides load-bearing capabilities.
The Design of Structural Hempcrete Blocks
Ken Meyer explained the core difference in these blocks, stating, “It has a frame inside it. It’s a glass-filled biocarbonate frame… and then the hempcrete is pressed around it.” This internal frame allows the block to serve as a structural component within a wall system. This design means that a single block can replace multiple conventional building materials:
- Sheetrock
- Insulation
- Timber framing
By integrating these functions, the structural hempcrete block system is intended as a scalable, lower-carbon alternative to conventional wall systems with improved fire resistance, durability, and overall building envelope performance.
Manufacturing and Supply Chain Impact
The new factory in Rock Valley, Iowa, is scheduled to receive its manufacturing equipment in December 2022 or January 2023. Once operational, the facility is projected to produce two blocks per minute, equating to over 700,000 structural hempcrete blocks annually when running three shifts. At full production, this capacity could supply enough wall material for approximately 500 perimeter walls of 2,000-square-foot homes each year.
This regional manufacturing model is a key part of Renewabuild’s strategy to support local farmers and processors. Ken Meyer, who also operates Complete Hemp Processing in Winfred, South Dakota, emphasized the need for outlets for hemp hurd. “At Complete Hemp Processing in Winfred, South Dakota, we decorticate hemp stalks. And we need a place to sell the hemp hurd. And our farmers need us to have a place to sell hemp hurd so they can put hemp in rotation with corn and soybeans,” Meyer stated in an interview with Lancaster Farming Industrial Hemp Podcast.
Renewabuild Great Plains is co-founded by Ken Meyer, John Peterson of Dakota Hemp, and Bill Brehmer of Renewabuild Great Plains, alongside a group of Iowa farmers who have invested in the project. This collaborative approach aims to build a robust local supply chain for industrial hemp and its derived construction materials.
Looking Ahead for Hempcrete Construction
The introduction of U.S.-manufactured structural hempcrete blocks represents a notable step in the adoption of hemp-based building materials. The concept of these blocks was first showcased in the U.S. at the Pennsylvania Farm Show in January 2018, where the Pennsylvania Hemp Industry Council displayed the Just BioFiber structural hempcrete block. The ongoing development and scaling of production, as seen with Renewabuild Great Plains, reflect a growing interest in sustainable construction practices and the industrial potential of hemp.
For more information on the industrial hemp sector in the region, resources include South Dakota Industrial Hemp Association and Dakota Hemp.
Disclaimer: This article is for informational purposes only and does not constitute medical advice. Hemp Gazette does not provide medical recommendations, diagnoses, or treatment plans. Always consult a qualified healthcare practitioner before making any decisions regarding your health or any medical condition. Statements concerning the therapeutic uses of hemp, cannabis, or cannabinoid-derived products have not been evaluated by Australia’s Therapeutic Goods Administration (TGA). Medicinal cannabis products in Australia are accessed via prescription pathways under TGA regulation.
