Given the significant environmental challenges posed by plastic waste, innovative reuse strategies are essential. This study seeks to bridge a gap in prior research by investigating the novel application of polyvinyl chloride drainage pipe waste (PVC) as a partial sand substitute in mortar, aiming to enhance both the thermal behavior and mechanical performance. Previous studies have noted that while integrating plastic waste into construction materials can enhance thermal properties, it frequently results in a reduction of mechanical strength. To address this issue, our study carefully considered the size of PVC aggregates. Seven substitution rates (0%, 5%, 10%, 15%, 20%, 25%, and 30% by weight) were evaluated through laboratory tests, including bulk density, water absorption, compressive and flexural strength, thermal conductivity, volumetric heat capacity, and thermal diffusivity. Additionally, numerical simulations using TRNSYS software on office buildings assessed the energy-saving potential. Furthermore, a multi-objective optimization approach was introduced to identify the optimal mix composition, balancing mechanical strength and thermal performance. Results showed that increasing PVC content improved thermal properties, with an optimal substitution rate also enhancing mechanical characteristics. Notably, a 30% replacement rate demonstrated significant energy savings, which could be further increased by increasing the mortar thickness.

eco-friendly mortar, plastic waste, mechanical characterization, thermal characterization, energy efficiency, optimization