Cianbro’s history in Madison, Maine, runs deep. In the 1980s, Cianbro, in a joint venture, built a state-of-the-art paper machine at the Madison Paper Mill. At the time, the project was considered one of the largest industrial and manufacturing projects that the company had ever taken on. With the expansion of the new paper machine, the mill was one of North America’s largest producers of supercalendered paper for magazine publications.

Operations at the mill came to a halt in 2016, as the demand for paper took a downturn. Now, with a new scope, the Madison mill will once again reclaim its significance as it becomes the home of the first wood fiber insulation manufacturer in North America.

In the fall of 2021, Cianbro began to retrofit the former mill into a manufacturing facility for TimberHP. The facility will bring carbon neutral wood fiber loose fill, batt, and board insulation to the residential and commercial markets in the United States. Already proven in Europe, these products will compete, both in performance and price, with insulation products already available today.

After mobilizing the site, the team began the rework of the existing underground utilities in the yard, including fire protection, sewer, and storm water drainage systems. Preparation of the existing building started with demolishing the concrete foundations, structural steel, and the infill of floor openings where the paper machine and other equipment used to sit. Cianbro reworked the existing infrastructure, including the high-voltage circuits, city water, and compressed air systems. In the spring of 2022, equipment foundations began, and in total, the team placed 1,800 yards of new concrete in and around the facility. In addition, Cianbro supplied and installed over 700 tons of structural steel for building reinforcements and structures that support equipment for the various stages in the manufacturing process, such as natural gas dryers, dryer tubes, and cyclones.

Installation of the new equipment started with a natural gas-fired boiler including steam, condensate, and gas piping systems. Cianbro also installed new chip handling equipment, chip digesters, refiners, gas dryers, loose-fill packaging equipment, and a complete batt and board manufacturing line. Additionally, the team supported the electrical, controls, and networking systems throughout the facility. In the spring of 2023, TimberHP commissioned and began production of the first product line, TimberFill. This was followed by the TimberBatt product in the fall of 2023, and TimberBoard early in 2024.

With limited early design, the biggest challenge for the team was keeping a smooth workflow between design engineering and material deliveries. The availability of materials and components had a major impact that changed the dynamics of the project. Delays outside of the team’s control required creative thinking within the schedule to maintain the customer’s original startup goals. With the project expanding to nearly double the originally anticipated scope, the team did a great job adjusting to the frequent changes.

The project benefited from a workforce of over 140 individuals, with the majority hailing from Maine, specifically from the surrounding Madison area. With many on the team having observed the mill’s closure in 2016, the team eagerly embraced the opportunity to be part of the retrofit of the mill for a new purpose. The prospect of working on such a project within the local community served as a strong motivator, and the unwavering commitment of the entire team played a pivotal role in its success!

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