Recycled Clay Brick Powder as a Dual-Function Additive: Mitigating the Alkali–Silica Reaction (ASR) and Enhancing Strength in Eco-Friendly Mortar with Hybrid Waste Glass and Clay Brick Aggregates

The construction industry’s escalating environmental footprint, coupled with the underutilization of construction waste streams, necessitates innovative approaches to sustainable material design. This study investigates the dual functionality of recycled clay brick powder (RCBP) as both a supplementary cementitious material (SCM) and an alkali–silica reaction (ASR) inhibitor in hybrid mortar systems incorporating recycled glass (RG) and recycled clay brick (RCB) aggregates. Leveraging the pozzolanic activity of RCBP’s residual aluminosilicate phases, the research quantifies its influence on mortar durability and mechanical performance under varying substitution scenarios. Experimental findings reveal a nonlinear relationship between RCBP dosage and mortar properties. A 30% cement replacement with RCBP yields a 28-day activity index of 96.95%, confirming significant pozzolanic contributions. Critically, RCBP substitution ≥20% effectively mitigates ASRs induced by RG aggregates, with optimal suppression observed at 25% replacement. This threshold aligns with microstructural analyses showing RCBP’s Al3+ ions preferentially reacting with alkali hydroxides to form non-expansive gels, reducing pore solution pH and silica dissolution rates. Mechanical characterization reveals trade-offs between workability and strength development. Increasing RCBP substitution decreases mortar consistency and fluidity, which is more pronounced in RG-RCBS blends due to glass aggregates’ smooth texture. Compressively, both SS-RCBS and RG-RCBS mortars exhibit strength reduction with higher RCBP content, yet all specimens show accelerated compressive strength gain relative to flexural strength over curing time. Notably, 28-day water absorption increases with RCBP substitution, correlating with microstructural porosity modifications. These findings position recycled construction wastes and glass as valuable resources in circular economy frameworks, offering municipalities a pathway to meet recycled content mandates without sacrificing structural integrity. The study underscores the importance of waste synergy in advancing sustainable mortar technology, with implications for net-zero building practices and industrial waste valorization.