Building materials can enable the recycling of sewage sludge from tannery wastewater treatment by infiltration/percolation over coal and clay waste. The process avoids energy-intensive operations and yields a stable and environmentally friendly product. The sludge under study is mainly composed of SiO₂, CaO, Al₂O₃, and Fe₂O₃, which is convenient to replace the mortar in cement. Different mortars were made by substituting a variable amount of sludge, from 0 to 30%, into the standard cement. The microstructure and mechanical properties of the mortar specimens were characterized after curing for 7 days and 28 days. The best properties were obtained with 15% sludge. Above 15%, the strength decreases at an early stage, as confirmed by SEM and XRD analysis, with more voids and ettringites at larger sludge content. The leaching tests of the mortar confirm that the cumulative values of heavy metals are far below the Deutsch regulatory limits (NEN 7043), justifying retention of the metals in the matrix. Radiological assessment of the sludge mortars also confirms their safety with the values of naturally occurring radioactive materials, surface radon exhalation and annual effective dose far below the required limits. The study suggests that 15% sludge can be used to sustainably replace cement and meet building safety requirement standards.

The sustainable management of dredged sediments poses a major environmental and economic challenge, particularly in Morocco, where large quantities are annually discarded as waste. Contributing to resource efficiency and circular economy objectives, this study represents the first systematic application research of Moroccan Mehdia Harbor sediments in mortar formulations. Three substitution strategies were investigated at substitution rates of 5–30%: (i) replacement of cement with fine sediments (series MA); (ii) replacement of sand with intermediate sediments (series MB); (iii) replacement of sand with sandy sediments (series MC). Mechanical testing at 28 days showed that both compressive and flexural strengths remained comparable to the reference mortar for substitution levels up to 10–15%, depending on sediment type. Beyond these limits, a marked strength reduction was observed, particularly for cement replacement with fine, clay-rich sediments. Mortars incorporating sandy sediments (MC) exhibited the best performance, maintaining over 80% of the reference compressive strength up to 15%. Leaching tests confirmed the environmental stability of all formulations, which remained within the “inert” waste classification up to 15% substitution. These findings demonstrate that dredged sediment incorporation in mortar is both technically and environmentally feasible for non-structural applications, promoting sustainable materials within a circular economy framework.