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Sisal fiber along with ZrO2 particles dispersed unsaturated polyester (UP) composites were fabricated by compression molding technique. The filler contents were varied from 5 to 45 wt% with a gradual increase of 10%. The structural investigation was done using Scanning electron microscopy, X‐ray diffraction, and Fourier transform infrared spectroscopy. Mechanical testing was performed through microhardness tester, tensile, flexural, and Izod impact test. The optimum mechanical properties were obtained at 35 wt% of filler incorporation within UP matrix followed by a slight deterioration at 45 wt%. Fractographic images of the composites display the phenomena of fiber pull‐out, debonding and breakage. The water absorption test was performed both at room temperature and boiling water temperature conditions. The thermal insulation measurement was performed by Kawabata method. POLYM. COMPOS., 40:2790–2801, 2019. © 2018 Society of Plastics Engineers [ABSTRACT FROM AUTHOR]