<p>This study explores the development of sustainable geopolymer concrete (GPC) paver blocks synthesized with red mud (RM) and ground blast furnace slag (GBS) suitable for heavy and very heavy traffic conditions. The investigation utilized a 10&#xa0;M sodium hydroxide solution with 50% RM and 50% GBS as source materials, maintaining a sodium silicate to sodium hydroxide ratio of 1.5 and an alkaline solution-to-binder ratio of 0.45. The objective was to prepare paver blocks for both heavy traffic (M50) and very heavy traffic (M55) conditions according to Indian standards. The methodology involved assessment of the mechanical properties of paver blocks, including compressive, flexural and tensile strength. Durability parameters like resistance against abrasion and water absorption were checked. The microstructural development of GPC paver blocks was examined through scanning electron microscopy and energy dispersive X-ray analyses. The sustainability of the paver blocks, checked through cost–benefit analysis, embodied carbon and embodied energy. Results demonstrated exceptional performance of GPC paver blocks with 28-day compressive, flexural and tensile strength 29, 25 and 67% more than the requirements meant for heavy traffic conditions (M55). The resistance against abrasion and water absorption of RM-GBS GPC paver blocks was 21 and 50% less than the requirements. The cost, carbon and energy performance of RM-GBS GPC paver blocks were 6, 40 and 44% better than normal concrete paver blocks. The findings highlight the viability of RM-GBS-based GPC as a sustainable alternative to conventional concrete for heavy-duty paver block applications, offering superior performance characteristics.</p> Graphical Abstract <p></p>