In Egyptian climates, an efficient insulating system could reduce air conditioner energy demand. Building insulation, especially waste-based insulation owing to its low cost, wide availability, and treatment of waste, became interesting. Thus, this study examined the effect of roofing tile samples made from 40% waste aluminum crushed and kaolin clay with different firing temperatures (900 °C, 1000 °C, and 1100 °C) on the internal air temperature and energy needed to cool social residential buildings built without climatic considerations in Egyptian climatic regions. Design-Builder (DB) was used to simulate the study regions for environmental performance and cooling effect. The study model was validated by comparing monthly energy use data with Aswan residential unit electricity bills. Sample S2, fired at 1000 °C, exhibited the lowest thermal conductivity and saved 4.7% to 13.33% of cooling energy across all climatic regions. In hot deserts, the roof tile sample (S2) could save till 8.99% of cooling energy. Aswan, a desert city, saves the most energy despite having a slight improvement rate 8.23% compared to other cities. Finally, the study supports sustainable design in the present and future. The sustainable design could substantially lower interior thermal temperature and cooling energy.