Integrated Embodied-Operational Carbon Reduction for Sustainable Egyptian Housing Through Wall-System Substitution

Rapid population growth is increasing housing demand and accelerating the expansion of the built environment in Egypt. However, practical and sustainable residential building decarbonization remains constrained by limited supplies of supplementary cementitious materials, limited structural timber resources, code restrictions on cement reduction, and cost sensitivity. This study evaluates two Egyptian multi-unit residential case studies—one affordable housing project and one middle-class housing project—to assess whether wall-system substitution can reduce both embodied and operational carbon under local material, code, and cost constraints. An integrated BIM-based digital twin workflow was used to link quantity takeoff, finite-element structural assessment, and whole-building energy simulation. An architectural BIM model was used for material quantification, wall-system definition, and energy-model inputs. A structural model was used to assess the effects of reducing wall density on reinforcement and concrete demand under gravity and seismic load combinations. Operational performance was assessed through cooling-focused energy simulations under hot-arid climatic conditions representative of Egypt’s new desert cities. Alternative wall systems were then evaluated through scenario- based material substitution and revised structural and energy assessments. The results show that reinforcement, concrete, and wall- core materials account for about 80% of total embodied carbon, while cooling accounts for about 72% of operational emissions. Non-structural cement uses, mainly mortars and finishes, account for 36% of total cement demand, ranging from 161 to 229 tons per building across the two case studies. Replacing conventional partition walls with lightweight, energy-efficient alternatives reduced embodied carbon by up to 35.2%, operational carbon by about 15.7% to 16.5%, and total life-cycle carbon by about 17.4% to 17.5% over a 60- year service life. The average savings per building corresponded to avoiding about 30 tons of steel, 165 m³ of ready-mix concrete, and 191 m³ of mortar, with net cost savings of about 3.15 million EGP per building. These results identify a practical pathway toward more sustainable, lower-carbon Egyptian residential buildings without increasing project cost.