Expanded polystyrene (EPS) is a material that may be harmful to human health. This is mainly because it releases specific chemicals during its manufacture, usage, and disposal. It is important to remember that the effects on health can change depending on the particular situation, exposure levels, and personal sensibilities. There are initiatives underway to address these environmental issues. Increasing EPS recycling rates, locating substitute materials, and encouraging appropriate disposal techniques are the main goals of several projects. Furthermore, studies into more environmentally friendly EPS substitutes for a variety of applications are still in progress. Creating a circular economy and lowering the total amount of single-use plastics used are two more aspects of larger plans to lessen the environmental impact of materials like EPS. The introduction of EPS cubes into concrete has reduced the adverse effects of EPS materials in the environment. This study substituted EPS, which is generated from industrial waste products, for aggregate. For an experimental study, a good-strength, sustainable concrete mix of grade M30 has been developed. In increments of 25%, five different mix proportions were evaluated for EPS cubes with size variations of 10 mm, 12 mm, and 20 mm. The range of 0 to 100% was studied. The replacement of EPS cubes by volume of course aggregates in the mixture yields the maximum increase in crushing, rupture, and bending strength, according to the mechanical properties of concrete that have been observed. This replacement ratio of 25% was shown to be efficient. The use of EPS materials in concrete is therefore shown to produce large reductions in environmental pollutants in addition to significant cost and energy savings. © 2025 Elsevier B.V., All rights reserved.