All processes
PRC.15 · Construction Process

Bio-Based Infill: Straw and Hemp-Lime

A bio-based material does not fear moisture: it fears moisture that cannot leave. The whole technique of these walls rests on one rule — keep the base high, the roof overhanging, and every layer more vapour-open as you move outwards.

Bale density
90–120 kg/m³
Straw moisture at installation
< 15 %
Lift above external level
≥ 30 cm
Hemp-lime drying
weeks, not days

Overview

TAV. 00

Straw and hemp-lime solve the same problem — filling the void of a timber frame with insulation — through opposite logics. Straw arrives ready made, in dense compressed bales that wedge between the studs: extremely low cost, high performance, but zero tolerance for moisture during installation. Hemp-lime is cast or sprayed around the frame like a lightweight concrete: it follows any geometry, leaves no voids and buffers humidity in a way no synthetic insulation can, but it dries slowly and carries no load. In both cases the design does not end at the wall: it starts with the overhanging roof and the raised base, because these materials are defended by the geometry of the building before they are defended by their own layers.

The site score

TAV. H
NOT TO SCALE1 of 5 layer in placeTimber frame and base detail

The detail of the craftthe base detail that saves the building

≥ 30GUAINARIEMPIMENTOGLI SCHIZZI DI PIOGGIA ARRIVANO A 30 cm DAL SUOLO
01Days 1–4

The frame and the raised base

Erecting the timber frame on a raised kerb, with a separating membrane and stud spacing matched to the bale dimensions.

Why it is done this wayThe base is where these buildings live or die. Straw and hemp-lime cope perfectly well with humidity cycles, provided they can dry; they do not cope with water rising from the ground or rain splashing back off the external paving. So the infill never starts at ground level: you begin from a kerb raised at least thirty centimetres, with a separating membrane between concrete and timber, and a water-tolerant material under the first course of infill. Stud spacing is not free either: with straw it matches the bale length, otherwise you end up cutting bales, and a cut bale loses density exactly where it was needed.
≥ 30 cm · lift above external level≥ 60 cm · recommended roof overhang= balla · stud spacing with straw
In handlaser level and squaredriver and structural screwsseparating membrane
roof completed before the infill, not after
The mistake that costs dearlyThe infill brought down flush with the external paving to avoid a step: rain splash repeatedly wets the bottom band of render and decay starts there, invisible until it is widespread.
Site supervision checkInfill lift above the finished external level; continuous separating membrane between kerb and timber; stud spacing consistent with the infill dimensions; roof overhang checked against the design and not reduced on site.
Raise the base and extend the eaves. Those two cheap moves save you everything else.site notebook — editorial synthesis
The beats — with site daysbeat 1 of 5
2–8 weekshemp-lime drying before rendering: rendering a still-damp cast seals the moisture in
7–10 daysscratch coat set before the body coat

click a beat · arrow keys ← → walk the site · dashed pauses are the chemistry at work

The question everyone asks

Why a rendered straw wall resists fire

TAV. G1

It is the immediate objection, and it is more interesting than it looks. Loose straw burns very well because it is full of air; straw compressed to a hundred and twenty kilos per cubic metre has no oxygen inside it and chars slowly, like a solid timber beam. On top of that sits the lime render, which is mineral and non-combustible, and which is in fact the wall's fire protection. The real danger is not in the finished building: it is on site, with the bales still loose and unprotected.

PAGLIA SFUSA · IN CANTIEREARIA FRA GLI STELI = COMBUSTIONE RAPIDAè la fase in cui servono le misure antincendioCOMPRESSA E INTONACATA · IN OPERANESSUN OSSIGENO DENTRO: CARBONIZZA LENTAl'intonaco minerale è la vera protezioneLE CLASSI DI RESISTENZA AL FUOCO SI DIMOSTRANO CON PROVE SUL SISTEMA COMPLETO, NON SUL SINGOLO MATERIALE

Fire behaviour is always demonstrated by testing the complete system — infill plus render, in its actual composition — and never inferred from a single material: what is explained here is the physical principle, not a substitute for certification.

Two infills compared

Straw bales or cast hemp-lime

TAV. G2

Straw insulates more and costs far less, but it imposes its module on the design and forgives no water on site. Hemp-lime insulates less for the same thickness but adapts to any shape, leaves no voids, adds mass and buffers humidity with an inertia you can feel in the shoulder seasons. The choice almost always comes down to two questions: how regular is the geometry, and how much time is there before rendering.

BALLE DI PAGLIA+ isola di più, costa pochissimo+ posa a secco, si intonaca subito− il modulo della balla comanda il progetto− nessuna tolleranza sull'umidità in cantiereGETTO DI CANAPA-CALCE+ si adatta a ogni forma, zero vuoti+ massa e regolazione dell'umidità− isola meno a parità di spessore− asciuga in settimane: blocca il cantiereIN ENTRAMBI I CASI IL TELAIO PORTA TUTTO: IL RIEMPIMENTO NON È MAI STRUTTURA

In both cases the infill carries no load: the structure is always the frame. Load-bearing straw bale construction does exist, but it is a separate technical and regulatory chapter, not a variant of the same installation.

How it ages (and what betrays it)

TAV. P
PIEDE BAGNATOInfill too close to the external level (phase 01): rain splash wets the bottom band in cycles, the material never fully dries and decay climbs from the base.
BALLA UMIDAStraw installed above fifteen per cent moisture (phase 03): it ferments inside the wall, losing performance, with a smell that appears only months later.
VUOTO IN SOMMITÀInfill settlement with no intermediate rails (phase 02): a continuous air channel is left under the head rail, with localised condensation and a linear heat loss.
CICLO CHIUSOCement scratch coat or film-forming paint (phases 04 and 05): permeability is reversed, moisture stays in the infill and the wall rots behind an apparently sound surface.
FESSURE DA RITIRORender applied too thick or over still-damp hemp-lime (phase 05): widespread cracking that opens water paths exactly where continuity was needed.

Questions from the site

TAV. Q
What about rodents?

It is objection number two after fire, and the answer is the same: it depends on how the wall is built, not on the material. Straw is the stalk of the plant, not the grain: it is not food. A rodent gets in if it finds a void and a way through, so the problem is solved by compaction — no voids — and by mechanically closing the edges, typically a fine wire mesh in the bottom band and around openings, under the render. A dense wall rendered on both sides offers neither space nor access.

How well does it really insulate, in numbers?

Straw sits in the range of the good natural insulants, with a conductivity of the same order as wood fibre; hemp-lime insulates less, because the mineral binder adds both conductivity and mass. But comparing conductivity alone is misleading: both have a thermal capacity and a moisture storage capacity that synthetic insulants do not, and in summer that translates into hours of thermal lag and a room that does not swing. In an honest comparison, a forty-centimetre straw build-up matches a much thinner synthetic one in winter, and clearly beats it in summer.

Who certifies a house like this, and will banks lend on it?

Structurally there is nothing unusual: the structure is a timber frame, calculated and filed like any other. The infill is an insulating material and must be declared as such, with its performance demonstrated by the supplier; the most delicate point is fire resistance, which must be demonstrated on the complete system by testing, not inferred. In practice the obstacle is not technical but a matter of familiarity: it pays to arrive at the planning office and at the lender with the system documentation already complete, because most objections arise from the fact that the person opposite has never seen a file like this.

How long does a straw wall last?

The oldest straw bale houses in Nebraska have passed the century mark, and they were built without any of today's understanding of moisture physics. Longevity does not depend on the straw but on three things: that water does not rise from below, that it does not get in from above, and that whatever does get in can leave. Translated to site: raised base, generous eaves, and no layer more vapour-tight as you move outwards. Respect those three and the wall outlasts the service life of most of the synthetic materials it could have replaced.

Materials involved

TAV. M