Bio-aggregate composites such as hemplime offer a more sustainable alternative to traditional walling infill material. Hemp-lime, whether in situ or prefabricated, is generally either cast or sprayed, which results in a directionally dependent, typically layered, physical structure. This paper considers the impact of compaction and layering on the directional thermal conductivity, compressive strength and internal structure of the material through use of a novel image analysis method. The results presented indicate that production variables have a significant, and crucially, directionally dependent impact on the thermal and mechanical properties of cast hemp-lime.