Although waste-To-energy plants allow reducing the mass and volume of municipal solid waste (MSW) incinerated, an average around 30 % of the total content remains as bottom ash (BA) and air pollution control (APC) ashes at the end of combustion process. While weathered bottom ash (WBA) is considered a non-hazardous residue that can be revalorized as a secondary aggregate, APC fly ashes generated during the flue gas treatment are classified as hazardous waste and are handled in landfill disposal after stabilization, usually with Portland cement (OPC). However, taking into account the amount of APC residues produced and the disposing cost in landfill, their revalorization is an important issue that could be effectively addressed. As MSW can be incinerated producing bottom ashes (BA) or air pollutant control (APC) residues, the development of a mortar formulated with APC fly ash as secondary building material is a significant risk to the environment for their content of heavy metals. In this way, Design of Experiment (DoE) was used for the improvement of granular material (GM) formulation composed by APC and OPC for further uses as road sub-base aggregate. DoE analysis was successful in the modelling and optimization the formulation as function of the mechanical properties and APC amount. Consequently, an optimal mortar formulation (OMF) of around 50 wt.% APC and 50 wt.% OPC was considered. The OMF leachates and abrasion resistance have been analyzed. These results have demonstrated the viability of OMF as non-hazardous material feasible to be used as secondary aggregate. Moreover, it would be possible to consider the environmental assessment of a GM composed by ≈20 wt.% of OMF and ≈80 wt.% of WBA in order to improve mechanical properties and heavy metals stabilization