Design and optimization of a lightweight, thermally insulated modular housing unit using hempcrete and ferrocement composites for disaster-resilient construction

Project Abstract

This study presents a comprehensive approach to designing and optimizing a lightweight, thermally insulated modular housing unit that leverages hempcrete and ferrocement composites to achieve disaster-resilient performance while promoting sustainable construction practices. The research integrates material science, structural engineering, and modular construction techniques to evaluate the synergistic benefits of hempcrete’s low density, high thermal resistance, and bio-based composition with ferrocement’s enhanced crack resistance, durability, and impact resistance. The abstract outlines a multi-phase methodology material characterization, mixture optimization, and composite behavior under service and extreme loading conditions, followed by modular unit design, performance simulation, and experimental validation. Material characterization focuses on the thermal, mechanical, and hygrothermal properties of hempcrete-ferrocement composites, including thermal conductivity, specific heat capacity, moisture migration, compressive strength, flexural strength, and fracture energy. An optimization framework employing response surface methodology and genetic algorithms seeks the optimal hemp hurds-to-binder ratio, lime content, reinforcing mesh configuration, and ferrocement texture to minimize thermal transmittance while ensuring structural adequacy under wind, seismic, and blast scenarios. The study also investigates the durability of hempcrete under moisture cycles, freeze-thaw conditions, and biodegradation risk, with protective coatings and fiber reinforcement explored to extend service life without compromising recyclability. The structural analysis evaluates the modular unit’s load-path efficiency, redundancy, and resilience to progressive collapse, using finite element modeling to simulate seismic waves, wind pressures, and impact loading. Nonlinear pushover analyses and dynamic time-history simulations are integrated to quantify ultimate capacity, post-peak behavior, and residual deformations. The design emphasizes lightweight geometries, slip-resistant joints, and rapid on-site assembly, while ensuring airtightness and acoustic comfort through envelope optimization. Life cycle assessment and cost-benefit analysis compare environmental impacts and total cost of ownership against conventional concrete and masonry systems, highlighting reductions in embodied energy, carbon footprint, and construction duration. Experimental validation includes scale-model testing of key subassemblies, including hempcrete-ferrocement panels, connection details, and modular joints, under environmental chambers and servo-hydraulic loading rigs. Fire performance assessments address self-extinguishing potential, charring behavior, and thermal protection of interior occupants. The research culminates in a holistic design framework and a set of actionable guidelines for practitioners, detailing material mix recipes, manufacturing tolerances, structural detailing, and retrofit strategies for disaster-prone regions. The anticipated outcomes demonstrate that hempcrete-ferrocement composites can deliver a favorable balance of lightness, thermal efficiency, and structural resilience, enabling rapid, sustainable deployment of modular housing without sacrificing safety or long-term performance.

Project Overview

What This Project Is About

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A plain-language overview of the topic and what the project investigates.

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The Problem It Addresses

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What problem or gap this project tackles and why it matters to the field or society.

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Objectives of the Project

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1. Identify lightweight, insulating materials suitable for modular housing 2. Explore hemp-based composites and ferrocement options for strength and durability 3. Develop a modular design that minimizes material use while meeting safety norms 4. Evaluate thermal performance and cost implications 5. Propose an optimization approach for manufacturing and assembly efficiency

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What You Will Do Step by Step

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Survey existing materials and methods, select hempcrete and ferrocement options, and design simple modular units.

Build small-scale samples to test strength, insulation, and moisture resistance.

Collect data on thermal performance, weight, and ease of assembly.

Use basic calculations to compare costs and environmental impact.

Propose an optimized modular configuration based on test results and practicality.

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Expected Outcome

A validated modular housing concept that balances light weight, insulation, durability, and ease of assembly, with a recommended material mix and assembly guidelines.