The current study intends to investigate the engineering properties of green polymer mortar (PM) composite by fully replacing conventional cement with polyurethane prepared from an agro-industrial waste for sustainable construction applications. Polyurethane was developed from cardanol derived from cashew nut shell oil (CNSO). The prepared polyurethane was used as a binder for polymer mortar composites. The PM composites were formulated using different percentages of prepared renewable polyurethane resin (14%, 12%, 10%) as a novel binder material (PUPM), different percentages of red mud (RM) and palm oil fuel ash (POFA) fillers (16%, 18%, 20%), and silica sand (zones I, II, III). ANOVA and Taguchi method was used to optimize the formulation parameters for PM composites, which were then evaluated for physicochemical properties, mechanical properties, acid resistance, and characterization using Fourier transform infrared (FTIR), scanning electron microscope (SEM), thermogravimetric analysis (TGA), and X-ray powder diffraction (XRD). The green PUPM composite can be used for precision tools, structural repairs, industrial flooring, etc. Graphical abstract: [Figure not available: see fulltext.]. © 2023, The Author(s), under exclusive licence to Springer Nature Switzerland AG.
