Novel Ceramic and Refractory Composites for Masonry Bricks and Blocks: A Systematic Review of Materials, Properties, and Sustainability

Masonry bricks and blocks are among the most widely used construction materials worldwide; however, their conventional production relies on energy-intensive firing processes and virgin raw materials, leading to significant environmental impacts. In response to increasing sustainability and decarbonization demands in the construction sector, numerous novel ceramic and refractory materials have been proposed for masonry applications. This systematic review provides a comprehensive assessment of recent advances in ceramic and refractory materials for masonry bricks and blocks, focusing on material classification, processing routes, microstructure–property relationships, and sustainability performance. Following the PRISMA 2020 guidelines, the peer-reviewed literature published between 2018 and 2025 was systematically identified, screened, and analyzed. An analytical framework based on well-established relationships from ceramic science was adopted to support consistent comparison of mechanical, thermal, acoustic, durability, and sustainability-related properties across heterogeneous material systems. Conventional fired ceramics, waste-derived ceramics, lightweight and porous systems, alkali-activated and unfired materials, and advanced engineered ceramics were comparatively evaluated. The results reveal a clear shift from dense traditional fired ceramics toward materials incorporating industrial and agricultural residues, engineered porosity, and low-temperature or unfired processing routes. Waste-derived and geopolymer-based systems demonstrate significant potential for reducing CO2 emissions and energy consumption while maintaining functional performance suitable for masonry applications. Lightweight and porous ceramics exhibit enhanced thermal and acoustic behavior, often accompanied by reduced mechanical strength, highlighting application-dependent trade-offs. Overall, this review provides an integrated perspective linking composition, processing, microstructure, performance, and environmental impact, identifying key research trends and knowledge gaps relevant to sustainable masonry construction.