In recent decades, relevant environmental and economic reasons have driven an increasing interest in using a large amount of recycled aggregate in replacement of natural ones to produce mortar and concrete. The present study aims to investigate the effect of substituting 100% of natural sand with recycled aggregate on fresh properties, mechanical properties, and the durability of a thixotropic and a self-leveling mortar. Recycled aggregate was characterized using X-ray diffractometry and energy-dispersive X-ray spectroscopy. Its morphology was investigated using scanning electron microscopy and automated morphological imaging. Recycled aggregate mortars showed a moderate decline in initial workability, as well as higher shrinkage and porosity than the control ones. The compressive strength of self-leveling mortars produced with recycled aggregate was only 6% lower than mortars produced with natural sand. The gap increased to 40% in the case of thixotropic mortars. The self-leveling recycled aggregate mortar showed equivalent resistance to freeze–thaw cycles and better sulfate resistance than the control one. The thixotropic recycled aggregate mortar showed comparable sulphate resistance and only slightly lower resistance to freeze–thaw cycles than the control one. Their capacity to relief stresses, due to hydraulic pressures and the formation of expansive products, arises from their higher porosity. Thermal stability of the prepared mortars, after a curing period of 90 days, up to 700 °C, was also investigated. A significant decrease in ultrasonic pulse velocity is observed in the 200–400 °C interval for all the mortars, due to the dehydration–dehydroxylation of calcium silicate hydrate. The overall decline in the strength of both the recycled aggregate mortars was comparable to the control ones. The results reported in the present investigation suggest that the selection of high-quality recycled aggregate helps to obtain good-quality mortars when a large amount of natural sand is replaced.

In recent years, the application of sustainable cementitious materials has become of great importance to improve buildings efficiency and to achieve carbon neutrality. Main goal of this work to study and develop BIOAERMAC, an innovative construction material with low density, composed of synthetic anhydrous calcium sulfate obtained as by-product in the industrial production of hydrofluoric acid and an aerating agent composed of microorganisms and peroxides, with the addition of rubber from end-of-life tires (ELTs). A density from 600 to 950 kg/m³ with a compressive strength up to 6.0 MPa and a thermal conductivity from 0.15 to 0.3 W/mK are the key performance metrics of BIOAERMAC composites. Experimental results showed an improvement in technical and energy performance, combined with a reduction in natural resource consumption and the wide quantity of by-product reintroduced into the production process.