Hempcrete is a sustainable biocomposite that can reduce buildings’ embodied energy while improving energy performance and indoor environmental quality. This research aims to develop novel insulating hemp-lime composites using innovative binder mixes made of recycled and low-embodied energy pozzolans. The characterization of composites’ mechanical and hygrothermal properties includes measuring compressive strength, splitting tensile strength, thermal conductivity, specific heat capacity, and moisture buffer capacities. This study also investigates the impact of sample densities and water content on compressive strength at different ages. The findings suggest that mixes with a 1:1 binder to hemp ratio and 300−400 kg/m³ density have hygrothermal and mechanical properties suitable for insulating infill wall applications. Hence, compressive strengths, thermal conductivity, and specific heat capacity values range from 0.09 to 0.57 MPa, 0.087 to 0.10 W/m K, and 1250 to 1557 J/kg K, respectively. The average moisture buffer value for all hempcrete samples of 2.78 (gm/m² RH%) indicates excellent moisture buffering capacity. Recycled crushed brick pozzolan can enhance the hygrothermal performance of the hemp-lime composites. Thus, samples with 10% crushed brick have the lowest thermal conductivity considering their density and the highest moisture buffer capacity. The new formulas of hydrated lime and crushed brick have mechanical properties comparable to metakaolin and hydraulic lime formulas.

A deep energy retrofit of building envelopes is a vital strategy to reduce final energy use in existing buildings towards their net-zero emissions performance. Building energy modeling is a reliable technique that provides a pathway to analyze and optimize various energy-efficient building envelope measures. However, conventional optimization analyses are time-consuming and computationally expensive, especially for complex buildings and many optimization parameters. Therefore, this paper proposed a novel optimization algorithm, MEVO (metamodel-based evolutionary optimizer), developed to efficiently identify optimal retrofit solutions for building envelopes while minimizing the need for extensive simulations. The key innovation of MEVO lies in its integration of evolutionary techniques with design-of-computer experiments, machine learning, and metaheuristic optimization. This approach continuously refined a machine learning model through metaheuristic optimization, crossover, and mutation operations. Comparative assessments were conducted against four alternative metaheuristic algorithms and Bayesian optimization, demonstrating MEVO’s effectiveness in reliably finding the best solution within a reduced computation time. A hypothesis test revealed that the proposed algorithm is significantly better than Bayesian optimization in finding the best cost values. Regarding computation time, the proposed algorithm is 4–7 times faster than the particle swarm optimization algorithm and has a similar computational speed as Bayesian Optimization.