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This article investigates experimentally and numerically the thermal performance of a new type of structural insulated panel (SIP) termed 'UWall'. The panel core consists of an ad-hoc waffle skeleton of Expanded Polystyrene (EPS), EPS beads mixed with cement mortar (Portland cement type I and recycled concrete aggregate), and two external water-proof cement boards. The experimental programme examined the panels in three Phases. In Phase 1, 200×200×100 mm block specimens were exposed to a temperature of 70°C for 12 hrs. It was found that the new UWall specimens had a better thermal performance (by up to 20%) over other types of walls typically used in house construction in Southeast Asia such as Mon block wall. In Phase 2, five scaled-down house units (1.5×1.5×2.8 m) were built in Thailand. Temperature and relative humidity outside/inside the units were continuously monitored for 7 days during the summer season. It was found that the new UWall has a good thermal resistance, reducing temperatures by up to 4°C compared to mon-block wall material. The house units were subsequently modelled in Abaqus® software, and the modelling approach proved accurate (within 10%) at simulating the thermal performance of the house units. UWall panels were also tested in bending to determine their structural capacity. It was found that the panels can be safely used as load-bearing walls for single-storey houses. Design charts are then proposed and used to design and build a full-scale house in Phase 3. In Phase 3, a 10×7 m full-scale single-storey house was built using the new UWall panels. Based on results from bioclimatic charts, it was found that daytime temperature and humidity in the full-scale house were deemed as uncomfortable. However, if air movement was provided, the house remained within the comfortable zone at all times. New design charts for full-scale houses with UWall are proposed to meet a desired user-comfort level. This study is expected to promote the use of SIPs in house construction in tropical climates, which in turn is envisaged to save energy and make construction more sustainable. • A new UWall made of recycled aggregate concrete, expanded polystyrene, and cement boards is proposed • Thermal and structural behaviour of new SIP UWall are tested using five scaled-down units and a full-scale house in Thailand • The UWall reduced indoor temperature in the full-scale house by 3–5°C compared to conventional walls • As finite element models of the houses matched well the test results (accuracy <10%), a parametric analysis was performed • New design charts to meet specific structural or thermal performances in full-scale houses are proposed [ABSTRACT FROM AUTHOR]