Amid the environmental impact of traditional construction, a humble, plant-based material is beginning to make waves—one block at a time. Hempcrete, a biocomposite made from the stalks of the industrial hemp plant, is turning heads not just for its sustainability, but for its strength, insulation value, carbon-storing capabilities, and surprising design flexibility.

Long relegated to the margins of building innovation, hempcrete is now experiencing a renaissance, with forward-thinking architects, builders, and factory operators exploring its potential for everything from residential homes to public infrastructure. Let’s explore how hempcrete is made, where it’s produced, how it’s being used in modern construction, and why its future looks more than promising.

What Exactly Is Hempcrete?

Hempcrete is not a substitute for concrete in structural applications—but it’s not trying to be. Instead, it excels as a natural, breathable, insulating material used in wall assemblies, floors, and roof infills. It’s made from three ingredients:

• Hemp hurds (the woody core of the hemp stalk),
• A lime-based binder (often a mixture of lime, clay, and pozzolans), and
• Water.

When mixed together and packed into forms around a structural frame, hempcrete cures into a firm, yet flexible matrix that insulates, resists fire and pests, regulates indoor humidity, and—most importantly—sequesters carbon throughout its life. Unlike concrete, it doesn’t off-gas harmful chemicals or require energy-intensive production.

For every cubic meter of hempcrete produced, approximately 110 kilograms of CO₂ are absorbed and locked away. It’s one of the few materials that make a building greener the more you build with it.

Where Hempcrete Is Being Made: A Look Inside the Leading Factories

While many startups and regional manufacturers are entering the hempcrete space, a few major players are helping drive large-scale adoption:

IsoHemp (Belgium)

Founded in 2012, IsoHemp has grown into one of Europe’s largest producers of hempcrete blocks. Its automated factory near Namur, Belgium, produces thousands of units per day, which are used in residential and commercial buildings across Europe. Their standardized blocks are designed for speed and performance in wall construction and are available in multiple thicknesses for varying climate zones.

Hempitecture (United States)

Based in Idaho, Hempitecture is the first U.S.-based company to build a large-scale hemp insulation factory. Partnering with domestic hemp growers, they are scaling up the production of HempWool (loose fiber insulation) and cast-in-place hempcrete materials. Their materials are already being used in schools, wellness centers, and even prefab modular housing.

HempFlax (Netherlands)

One of the pioneers in European hemp processing, HempFlax has diversified its business across industrial applications, including construction. With operations in the Netherlands, Germany, and Romania, they supply hemp fibers and hurd to companies developing insulation panels, hempcrete, and green packaging materials.

As more countries legalize and regulate industrial hemp production, these types of facilities are expected to proliferate—especially in North America, where climate-conscious building codes are being rewritten to allow for low-carbon materials.

How Hempcrete Is Being Used in Construction

Hempcrete’s greatest strength lies in its versatility. Here are a few ways it’s already transforming modern building practices:

Wall Insulation and Infill Panels

Hempcrete is most commonly used to form non-load-bearing walls around timber or steel framing. It can be poured into formwork on-site or used in pre-cast panels for modular builds. In both cases, it provides exceptional thermal resistance (R-values of R-2 to R-3 per inch), reducing the need for additional HVAC equipment.

Floor and Roof Insulation

In addition to walls, hempcrete is being used as a subfloor insulation layer and for flat roof insulation, particularly in eco-homes and Passive House designs. Its moisture-buffering properties help prevent mold and mildew—an attractive feature for allergy-sensitive occupants.

Modular and Prefabricated Housing

Prefabricated wall panels filled with hempcrete are gaining traction in the offsite construction world. By combining the sustainability of hemp with the speed of prefab, companies are creating zero-energy and low-impact homes at competitive cost points. Hempitecture and a handful of startups in Canada and Australia are already experimenting with full-panelized hemp-based modular units.

Renovations and Retrofits

Because of its breathability and low weight, hempcrete is ideal for restoring older buildings—especially stone or masonry structures. It allows historic walls to maintain their natural moisture balance while adding insulation and fire resistance.

Hempcrete’s Role in the Future of Construction

Hempcrete isn’t a fringe experiment anymore—it’s on track to become a central player in the global push toward sustainable building materials. Here’s why:

Carbon-Negative by Design

In an era of climate urgency, materials that draw down carbon are worth their weight in gold. Hempcrete not only stores carbon from the hemp plant but also benefits from lime’s long-term carbonation process—absorbing more CO₂ over time.

Healthier Indoor Environments

As the world embraces wellness architecture, materials like hempcrete offer a clear advantage. They’re VOC-free, resist mold and pests, and regulate humidity—making them perfect for schools, healthcare facilities, and homes alike.

Regulatory Acceptance Is Growing

In 2022, the U.S. International Code Council accepted a proposal to include hemp-lime construction in the 2024 International Residential Code (IRC). This is a major milestone for builders hoping to use hempcrete without jumping through code interpretation hoops.

A Boon to Rural Economies

Hempcrete encourages local, regenerative agriculture. The hemp plant matures in 90–120 days, requires minimal pesticides, and improves soil health. For rural areas looking to revitalize through green industry, hempcrete manufacturing offers a compelling model.

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Challenges Ahead

Despite its promise, hempcrete faces hurdles. Scaling up requires consistent hemp supply chains, better-trained builders, and public awareness. In some markets, cement and synthetic insulation still dominate because of perceived cost advantages. But as hempcrete technologies become more automated—and as climate regulations stiffen—those advantages may quickly reverse.

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A Material Whose Time Has Come

In the rush to find climate-resilient, low-impact solutions for the built environment, hempcrete checks nearly every box: renewable, breathable, healthy, and beautiful. What was once a niche green building trend is now evolving into a global movement—one bale, block, and panel at a time.

The future of construction won’t just be smarter—it will be greener, lighter, and, quite possibly, full of hemp.

CHECK OUT HempBuild Magazine

In the heart of Utah’s housing affordability crisis, Elevation Construction is pioneering a transformative approach to homebuilding. By embracing modular construction and innovative design, the Sandy-based company is delivering high-quality, affordable homes that challenge traditional industry norms.

Building the Future: Modular Innovation

Elevation Construction, led by CEO Brody Lambert, utilizes prefabricated wall panels from Livio, which come equipped with integrated plumbing and wiring. These cold-formed steel structures are both fire-resistant and energy-efficient. Remarkably, a complete home can be assembled in just 12.5 hours, allowing homeowners to walk through their new residence the very next day.

Complementing this rapid construction is an innovative foundation system from Provo-based SimplyBilt. This foam-insulated foundation requires only 12 inches of excavation, significantly reducing labor costs and enhancing energy performance.

Elevation Construction’s Leadership

The Flex Home: Affordable and Adaptable

At the core of Elevation’s offerings is the “Flex Home”—a 1,250 sq. ft., 3-bedroom, 1.5-bath single-family home priced at $299,000. Designed with future growth in mind, these homes feature expandable foundations, allowing for additions such as garages, master suites, or accessory dwelling units (ADUs). This flexibility enables homeowners to adapt their living spaces as their needs evolve.

Moreover, new lending policies permit buyers to include potential ADU rental income when qualifying for a mortgage, making these homes accessible to households earning between $70,000 and $120,000 annually.

Challenging the Status Quo

Elevation Construction’s commitment to affordability has not gone unnoticed. By intentionally leaving $30 to $40 per square foot of equity on the table for buyers, the company diverges from traditional homebuilding models that prioritize higher margins. This approach has led to collaborations with like-minded partners, including landowners willing to defer lot payments and municipalities open to approving smaller lots.

The city of Ephraim was the first to embrace this model, paving the way for additional projects in Grantsville, Nephi, Helper, and Hurricane. Elevation is also in discussions with state officials about utilizing Trust Lands to expand affordable housing developments.

A Vision for Sustainable Growth

Elevation Construction’s innovative approach offers a compelling solution to Utah’s housing challenges. By integrating modular technology, efficient construction methods, and adaptable designs, the company is redefining what affordable housing can look like—without compromising on quality or livability.

As Utah continues to grapple with housing affordability, Elevation Construction’s model presents a scalable and sustainable path forward, demonstrating that innovation and compassion can coexist in the pursuit of the American Dream.

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Credit: This blog post is based on the article “Modular, Flexible, Affordable: How Elevation Construction is Quietly Reinventing Housing in Utah” by Mark Tullis, published on May 8, 2025, on TechBuzz News. Read the full article here: TechBuzz News.

In residential construction, the demand for energy-efficient and easy-to-install building materials is higher than ever. Enter Blueskin® VPTech™, an innovative solution from Henry® Company that combines multiple protective layers into a single, user-friendly panel. This product is particularly beneficial for non-professional builders seeking to enhance their projects with professional-grade materials.​

all photos – Blueskin® VPTech™

What is Blueskin® VPTech™?

This all-in-one panel simplifies the construction process by eliminating the need to install these components separately. The result is a more efficient building process that doesn’t compromise on quality or performance.​

Key Benefits for Non-Professional Builders

1. Simplified Installation

Traditional methods require multiple steps to install insulation, air barriers, and seam sealing. Blueskin® VPTech™ streamlines this by combining all three into one panel, reducing installation time by up to 30%. Its lightweight design and ease of handling make it ideal for DIY projects.​

2. Enhanced Energy Efficiency

Each panel offers an R-value of 5 per inch of Graphite Polystyrene (GPS) insulation, contributing to better thermal performance. This efficiency can lead to lower energy bills and a more comfortable living environment.​

3. Superior Moisture and Air Protection

The integrated WRB and seam sealing provide a continuous air barrier, reducing air leakage and preventing moisture intrusion. This self-sealing feature around nails and fasteners ensures long-term durability and protection against the elements.​

4. Compliance with Energy Standards

Blueskin® VPTech™ helps in achieving a lower Home Energy Rating System (HERS®) score and contributes to ENERGY STAR® and Zero Energy Ready Home (ZERH) program requirements. This compliance is beneficial for homeowners aiming for energy-efficient certifications.​

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Installation Tips for DIY Enthusiasts

• Preparation: Ensure the substrate is clean and dry.
• Cutting: Panels can be easily cut to size using standard tools like utility knives.
• Sealing: Pay attention to sealing all seams and penetrations to maintain the integrity of the air and moisture barrier.
• Safety: Always follow safety guidelines and wear appropriate protective gear during installation.​

Blueskin® VPTech™ offers a practical and efficient solution for non-professional builders seeking to enhance their construction projects. Its integrated design simplifies installation, improves energy efficiency, and provides superior protection against moisture and air infiltration. By choosing Blueskin® VPTech™, DIY enthusiasts can achieve professional results with greater ease and confidence.​

For more information and detailed installation guides, visit the Henry® Company website.

Gary Fleisher

Contact Gary

Gary Fleisher is the Leading Observer of the Offsite Housing Construction Industries. He has been actively involved in researching and writing about the latest trends and developments in the industry for over a decade now.

With his extensive knowledge and experience, Gary has emerged as a go-to expert for businesses looking to stay ahead of the curve in the modular construction industry. In addition to his work as an editor, he is also a sought-after speaker and consultant who has helped numerous companies achieve strategic and operational success.

Imagine a factory where robots don’t just follow orders—they think, adapt, and optimize on the fly. That’s the reality with Framebotix’s Artificial Intelligence Pack, a cutting-edge solution that’s redefining automation in manufacturing.​

Smarter Robots, Seamless Production

At the heart of Framebotix’s innovation is their AI Pack, designed to empower autonomous robotic digital factories. This isn’t just about programming robots to perform tasks; it’s about giving them the intelligence to make decisions, adapt to changes, and optimize processes in real-time.​

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The AI Pack integrates machine learning and computer vision, enabling robots to analyze CAD data and automatically select the appropriate tools and machining parameters. It considers the condition of raw materials and the robot system itself, ensuring precision and efficiency from design to production.

Real-Time Adaptability

One of the standout features is the system’s ability to adapt to changing conditions. Whether it’s a variation in material quality or an unexpected change in the production environment, the AI algorithms adjust operations on the fly. This level of adaptability minimizes downtime and maintains consistent product quality.​

Predictive Maintenance and Optimization

Beyond immediate production tasks, the AI Pack also plays a crucial role in predictive maintenance. By continuously monitoring machine performance, it can anticipate potential issues before they lead to breakdowns, scheduling maintenance proactively. This not only extends the lifespan of equipment but also ensures uninterrupted production schedules.​

Efficiency and Sustainability

Efficiency isn’t just about speed; it’s also about resource management. The AI Pack optimizes material usage, reducing waste and promoting sustainable manufacturing practices. By ensuring that every cut and movement is calculated for maximum efficiency, it supports both economic and environmental goals.​

Real-World Applications

Framebotix’s AI Pack is already making waves in various industries. From woodworking and stone processing to metal and carbon fiber manufacturing, the technology is proving its versatility and effectiveness. Companies like Anton Frei, Braun, and Wingcopter are leveraging this AI-driven approach to enhance their production capabilities.

The Future of Manufacturing

As industries continue to evolve, the integration of intelligent systems like Framebotix’s AI Pack will become increasingly essential. By combining advanced robotics with real-time data analysis and decision-making capabilities, manufacturers can achieve unprecedented levels of efficiency, quality, and adaptability.

In a world where change is constant, having a manufacturing system that can think and adapt is no longer a luxury—it’s a necessity. Framebotix’s Artificial Intelligence Pack is leading the charge, setting new standards for what automated production can achieve.

For more information on Framebotix’s Artificial Intelligence Pack and how it’s transforming manufacturing, visit their official website.

Gary Fleisher

Contact Gary

Gary Fleisher is the Leading Observer of the Offsite Housing Construction Industries. He has been actively involved in researching and writing about the latest trends and developments in the industry for over a decade now.

With his extensive knowledge and experience, Gary has emerged as a go-to expert for businesses looking to stay ahead of the curve in the modular construction industry. In addition to his work as an editor, he is also a sought-after speaker and consultant who has helped numerous companies achieve strategic and operational success.

Not long ago, the term offsite construction called to mind sprawling modular factories with long-term leases, high capital costs, and rigid logistics pipelines. But that definition is evolving—and fast.

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Enter the pop-up offsite factory, an agile, location-specific production solution that’s gaining attention in North America after proving its value in Europe and Australia. These compact, temporary manufacturing hubs are turning the traditional model on its head—and it’s about time.

What Exactly Is a Pop-Up Offsite Factory?

A pop-up factory is a temporary or mobile offsite manufacturing facility strategically set up near a specific project or development zone. Rather than producing modules or components hundreds of miles away and shipping them cross-country, pop-ups bring production closer to where homes or buildings will actually be placed.

Think of it as setting up a jobsite-adjacent mini factory that can produce panels, volumetric modules, components—or a hybrid of all three—based on the project’s needs. Once the project is complete, the factory can be disassembled, moved, or even repurposed.

These facilities aren’t just about novelty; they’re about speed, reduced transportation costs, minimal site disruption, and better oversight.

Why Are They Gaining Traction Now?

Pop-up factories aren’t a brand-new concept—but they’re certainly having a moment.

Several factors are converging to make them more attractive than ever:

• Rising transportation and fuel costs are eating into profit margins and delivery timelines.
• Workforce shortages make it hard to staff permanent facilities in remote areas.
• Large-scale affordable housing developments are increasingly being planned in areas without nearby modular production capacity.
• Communities want localized economic impact—and pop-ups bring jobs and innovation right to them.

For some developers and builders, the old model—hauling volumetric boxes from a regional factory—is simply not feasible anymore. It’s too slow, too expensive, and sometimes just too far away. Pop-up factories provide a smarter, leaner alternative.

Real-World Use Cases: It’s Already Happening

Pop-up factory models are already being tested and refined in places like:

• The UK, where several modular housing developers have established temporary production lines next to urban infill projects.
• Australia, where pop-ups are used in remote regions to address indigenous housing and mining workforce needs.
• Rural North America, where permanent factories often won’t pencil out, but a pop-up could meet demand for one large project.

An Amazing In-Depth Interview with Thunderhaus Innovator – Paul Richards

Even FEMA and disaster response organizations are looking into pop-up manufacturing as a way to rapidly respond to housing needs after wildfires, hurricanes, or other emergencies—bringing both construction and hope closer to where it’s needed most.

Not a One-Size-Fits-All Solution

While pop-ups are exciting, they’re not a silver bullet. These operations require:

• Fast permitting and code compliance,
• Mobile or modular production equipment,
• Reliable local subcontractor integration,
• And logistical mastery to avoid bottlenecks.

They also need modular thinkers—those who aren’t tied to traditional definitions of a factory and are willing to reinvent the process based on location, labor availability, and community needs.

What Could Pop-Up Factories Look Like in the U.S.?

Imagine a developer planning a 500-home project in a state with limited offsite infrastructure. Instead of battling for production slots at a distant factory, they build a pop-up plant 10 minutes from the site. Panels or modules are built under controlled conditions and delivered across the street, rather than across the state.

That’s not fantasy—it’s already in the planning stages in several states, particularly in underserved rural areas and tribal communities.

Some manufacturers are even exploring Factory-as-a-Service (FaaS) business models, where they lease mobile production capabilities to developers or general contractors, complete with on-site training and startup consulting.

When Will They Start “Popping Up”?

They already are—just quietly, and often under different names like “micro-factories” or “temporary satellite facilities.” But over the next few years, expect to see more builders and developers waking up to the potential of portable, local, and adaptable manufacturing.

Pop-up offsite factories might not replace the mega-factories—but they will absolutely complement them, especially in places where conventional approaches just can’t get the job done on time or on budget.

In a world of housing shortages, strained logistics, and community pushback, the pop-up factory just might be the offsite solution we didn’t know we needed—until now.

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In a quiet field somewhere in North Dakota, rows of tall, leafy hemp plants sway in the wind. A few states away, in Georgia, acres of bamboo stretch to the sky. And in countless corners of the world, crops once used for textiles, food, or insulation are now being reimagined as walls, roofs, and even entire homes.

Welcome to the world of bio-based building materials—a movement where the future of housing starts in the soil and ends in a structure. For modular and offsite construction innovators, the journey from field to foundation isn’t just about sustainability. It’s about opportunity.

Let’s dig into how these materials are grown, processed, and now woven into the very framework of tomorrow’s buildings—and why offsite construction might be the best place for this revolution to take root.

The Roots of Change: Where It All Begins

The term “bio-based” refers to materials derived from living or once-living organisms—typically plants. These include hempcrete, bamboo panels, flax-based insulation, straw bales, and mycelium bricks (yes, mushrooms). Unlike traditional materials that require mining, smelting, or high-carbon production processes, bio-based products often regenerate yearly, absorb CO₂ during growth, and can break down harmlessly at end of life.

But these aren’t backyard garden materials—they’re becoming serious contenders for structural and thermal performance. Hempcrete, for example, offers excellent insulation and vapor permeability while being fire-resistant and carbon-negative. Bamboo is stronger than steel in tension and can be processed into sleek laminated panels rivaling engineered wood.

As demand grows for homes that are healthier to live in and lighter on the planet, the raw materials are literally sprouting beneath our feet.

Harvesting the Potential

One reason bio-based materials are catching on now is timing. Climate anxiety is high. Government incentives are shifting. Builders are seeking greener materials that don’t cost double. And modular construction is poised to take full advantage.

Why? Because offsite builders operate in controlled environments where new materials can be tested, refined, and scaled. You’re not battling weather delays or inconsistent labor on-site. You can prototype a wall panel made from hemp-lime composite on Monday and tweak the process by Wednesday. That’s a level of agility that site-built contractors can only dream of.

Factories that partner directly with growers or regional suppliers also stand to benefit from material consistency and price stability. As global supply chains wobble, building local may not just be eco-friendly—it might be necessary.

From Field to Factory: A Modular Match

Let’s say you’re building a small-footprint modular home with high thermal requirements and an eco-conscious client base. Traditionally, you might use fiberglass insulation and standard gypsum board. But imagine this:

• Walls framed with laminated bamboo
• Insulated with flax or straw panels
• Sealed with lime plaster
• Wrapped in mycelium board for breathability and fire resistance

Every one of those materials is plant-based, and every one of them can be pre-assembled in an offsite production facility. The result? A modular home with significantly lower embodied carbon, better indoor air quality, and a compelling story that resonates with next-gen buyers.

That’s not fiction. That’s what a growing number of European factories—and a few bold U.S. operations—are doing right now.

Barriers Still Sprouting

Of course, not everything’s rosy in the bio-based world. There are real challenges that make some factory owners raise an eyebrow:

• Code compliance: Many building officials still don’t know what to do with hempcrete or straw walls. Testing and certifications lag behind.
• Supply chain limitations: Consistent sources of plant-based materials aren’t available nationwide. This makes regional adoption more feasible than national rollout (for now).
• Processing complexity: Turning raw plant material into construction-grade components isn’t easy. It requires drying, treatment, forming, and quality control that not all startups are ready to handle.

But none of those are deal-breakers. They’re infrastructure problems, not product problems. And infrastructure can be built.

What’s in It for Offsite?

Offsite construction has always been about optimization—doing more with less, faster, cleaner, and more consistently. Bio-based materials offer the same logic: more performance from less input, faster renewability, cleaner lifecycle, and consistent thermal or structural behavior once scaled.

They also offer a marketing advantage. People want to live in homes that feel like they belong to the earth, not ones built like a machine. If a modular factory can tell a client, “This home was grown before it was built,” that’s a story that sticks.

We’re entering a time where materials need to do more than just meet spec sheets. They have to meet expectations, values, and climate goals. And if you’re in offsite construction, you’re already ahead of the curve. Why not stay ahead by planting something new?

Green Shoots of Promise

The rise of bio-based building isn’t a flash in the pan—it’s a seedling industry, still growing but deeply rooted in both innovation and common sense. As more offsite factories explore ways to differentiate themselves, solve climate challenges, and meet shifting market demands, the field-to-foundation model is going to bloom.

So the next time someone tells you modular homes are just “boxes,” you can smile and say, “Yes—and some of us grow the box before we build it.”

Want to see which plant-based building startups are making waves in offsite? Stay tuned for our next piece where we spotlight 5 innovators quietly changing the way homes are grown.

Gary Fleisher

Contact Gary

Gary Fleisher is the Leading Observer of the Offsite Housing Construction Industries. He has been actively involved in researching and writing about the latest trends and developments in the industry for over a decade now.

With his extensive knowledge and experience, Gary has emerged as a go-to expert for businesses looking to stay ahead of the curve in the modular construction industry. In addition to his work as an editor, he is also a sought-after speaker and consultant who has helped numerous companies achieve strategic and operational success.