<p>The rapid increase in population, urbanization, and industrialization has accelerated municipal solid waste (MSW) generation, while inadequate disposal practices cause severe land, water, and air pollution. Incineration offers an effective way to reduce MSW volume and extend landfill capacity, yet the resulting MSW incineration ashes (MSWIA) pose disposal challenges. Recent studies suggest their potential in construction materials. This work investigates the feasibility of incorporating MSW bottom ash (MSWIBA) and fly ash (MSWIFA) into paver block production for low-volume traffic areas. The ashes were characterized for particle size distribution, mineralogy, morphology, and chemical composition using laser particle size analysis, X-ray diffraction, scanning electron microscopy, and X-ray fluorescence respectively. M30 grade concrete prepared with 20% natural sand replaced by MSWIBA and 10% coal fly ash replaced by MSWIFA achieved 28-day mechanical performance comparable to conventional mixes. Durability tests, including water permeation, rapid chloride permeability, and abrasion resistance, confirmed that MSWIBA substitution did not compromise concrete’s quality. Leaching analysis indicated heavy metal concentrations within USEPA regulatory limits, demonstrating effective immobilization and environmental safety. The embodied energy of paver blocks was ~1812 MJ/m³ for both control and MSWI-based mixes, with cement contributing over 90% of the total. Moreover, paver blocks incorporating up to 20% MSWIBA and 10% MSWIFA met the requirements of IS 15658:2006. The study highlights MSWIA as a sustainable alternative for large-scale paver blocks production, offering environmental benefits, resource conservation, and safe utilization of incineration residues.</p> Graphic Abstract <p></p>