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This work was focused on evaluating the suitability of replacing Portland cement (PC) by 5, 10 and 15 mass % of activated alum sludge waste (AAS) as a pozzolanic material. Exploitation of low-cost nanocomposite for bolstering the physical, mechanical, and stability against firing of PC–AAS-hardened composites was inspected. CuFe2O4 spinel nanoparticle with average particle size (~ 50 nm) was prepared. Inclusion of CuFe2O4 spinel in different PC–AAS-hardened composites bolsters their physicomechanical features at almost normal curing ages as well as their stability against firing. The positive impact of synthesized CuFe2O4 spinel was affirmed via TGA/DTG and XRD techniques, which indicated the presence of diverse hydration yields such as CSHs, CASHs, CFSH, and CuSH that enhance the overall physicomechanical characteristics and thermal stability of various PC–AAS-hardened composites. The composite containing (90 PC–10 AAS waste–2 CuFe2O4) offers many benefits from the economic and environmental view. Graphical abstract

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