The construction industry is under growing pressure to adopt sustainable practices that minimize environmental impact and promote resource efficiency. This study investigates the development of lightweight aluminium foam blocks incorporating agricultural and industrial byproducts, such as sawdust, sugarcane waste, aluminium scrap, aluminium powder, and fly ash. Hydrated lime and cement are utilized as binders, complemented by M-sand, to enhance the durability and structural integrity of the blocks. Key material properties were evaluated in preliminary tests. Aluminium scrap forms the primary matrix, while sawdust and sugarcane waste act as fibrous fillers, contributing to lightweight properties and thermal insulation. The cellular structure of the blocks enhances thermal and acoustic insulation by trapping air, making them ideal for applications such as partition walls, noise barriers, and fire-resistant construction. The results confirm that aluminium foam blocks achieve a compressive strength of 5.2 MPa, making them structurally comparable to AAC blocks (4.5 MPa) while remaining lightweight (800 kg/m3 vs. 600 kg/m3 for AAC). Fire resistance tests at 800 ℃ confirmed non-flammability with minimal weight loss (2.5%). Microstructural studies, including XRD, SEM, and EDS, revealed well-distributed pores and stable crystalline phases, ensuring improved insulation and mechanical performance. Rapid Chloride Permeability Tests (RCPT) demonstrated superior resistance to chloride penetration, enhancing durability in humid environments. The use of agricultural and industrial waste promotes sustainability and lowers production costs. These findings demonstrate that lightweight aluminium foam blocks offer a viable, eco-friendly alternative to conventional construction materials, paving the way for sustainable, energy-efficient building solutions.