Hygrothermal and mechanical characterization of novel hemp-lime composites with enhanced consistency

Hemp-lime composites have captured attention in the construction industry due to their sustainability and excellent hygrothermal performance. However, variability and inconsistent performance have hindered their widespread adoption. This research introduces a novel approach to improve the uniformity and hygrothermal characteristics, aiming for reproducibility and consistency comparable to traditional insulation materials. This method included (1) reducing hemp particle size to coarse (1.33 mm), medium (0.92 mm), and fine (0.72 mm) particles; (2) maximizing the hemp proportion to 70 % by weight; and (3) standardizing dry density using vibration techniques. The findings indicate dry density variability reduction in all samples, with a coefficient of variation ranging from 0.16 % to 2.36 %. The hygrothermal analysis demonstrates enhanced insulation and moisture-buffering properties, along with reduced directional disparity in thermal conductivity (1.2–6.8 %) compared to the control sample, particularly in samples with fine particle sizes. Thermal conductivity was within the range of 0.0535–0.0667 W/m K, considerably lower than previously reported values. Also, a positive correlation is observed between moisture-buffering and hemp ratio, indicating that higher hemp ratios in the composite lead to increased moisture capacity, with moisture buffer values of 2.47, 2.28, and 2.12 g/m² RH corresponding to the binder-to-hemp ratio of 30:70, 40:60, and 50:50 by weight, respectively. • Three uniform hemp shiv sizes and vibration casting reduced property variability. • The dry density variation coefficient ranged from 0.16 % to 2.36 %. • Thermal conductivity was from 0.054 W/m K (140 kg/m³) to 0.067 W/m K (200 kg/m³). • The new production approach reduced the anisotropic behavior to 1.2–6.8 %. • Average moisture buffer values ranged between 2.12 and 2.47 g/m² RH.