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The introduction of dyeing sludge in the fired brick production is an economic and practical disposal approach. Wet dyeing sludge with high moisture usually produces block mass during mixing process of raw materials, not only reduces the production efficiency but negatively impacted products engineering properties. This study proposed a highly efficient method, wet sludge firstly being pelleted and then introduced in the production of fired bricks, to reduce the negative impacts on mixing process and the products quality. It was proved that the introduction of dyeing sludge pellets remarkably improved physical and mechanical properties of fired bricks. Especially, water absorption declined by 12% and compressive strength increased by 35% comparing with dyeing sludge without pelleting. The engineering properties of fired bricks containing 25 wt% sludge pellets are similar with that containing 15 wt% sludge without pelleting. The decrease in water absorption and porosity is mainly attributed to the reduction in number and volume of pores with diameter below 100 nm. It was considered that pellets with greater density and higher strength might play a role as aggregate to improve compressive strength. However, the introduction of sludge pellets with particle size over 8 mm is adverse to improving properties of products, because a large amount of macropore with diameter over 100 μm is produced, and destroys the homogeneous and compact structure of products. The optimal sludge pellet size is in the range of 2–6 mm based on products performance. The leaching toxicity of heavy metals from products is far lower than regulatory limitation. This study provides an advanced method to promote the disposal efficiency of solid waste and improve the engineering quality of products. • The introduction amount of dyeing sludge is promoted remarkably. • Physical and mechanical properties are improved significantly. • The optimal particle size of sludge pellets is 2–6 mm. • Pore volume below 100 nm in fired brick are reduced. [ABSTRACT FROM AUTHOR]