Short- and Long-Term Mechanical and Durability Performance of Concrete with Copper Slag and Recycled Coarse Aggregate Under Magnesium Sulfate Attack

Sustainability in the construction sector has become a fundamental objective for mitigating escalating environmental challenges; given that concrete is the most widely used man-made material, extending its service life is therefore critical. Among durability concerns, magnesium sulfate (MgSO4) attack is particularly deleterious to concrete structures. Therefore, this study investigates the short- and long-term performance of concrete produced with copper slag (CS)—a massive waste generated by copper mining activities worldwide—employed as a supplementary cementitious material (SCM), together with recycled coarse aggregate (RCA), obtained from concrete construction and demolition waste, when exposed to MgSO4. CS was used as a 15 vol% cement replacement, while RCA was incorporated at 0%, 20%, 50%, and 100 vol%. Compressive strength, bulk density, water absorption, and porosity were measured after water curing (7–388 days) and following immersion in a 5 wt.% MgSO4 solution for 180 and 360 days. Microstructural characteristics were assessed using scanning electron microscopy (SEM), X-ray diffraction (XRD), thermogravimetric analysis with its differential thermogravimetric derivative (TG-DTG), and Fourier transform infrared spectroscopy (FTIR) techniques. The results indicated that replacing 15% cement with CS reduced 7-day strength by ≤10%, yet parity with the reference mix was reached at 90 days. Strength losses increased monotonically with RCA content. Under MgSO4 exposure, all mixtures experienced an initial compressive strength gain during the short-term exposures (28–100 days), attributed to the pore-filling effect of expansive sulfate phases. However, at long-term exposure (180–360 days), a clear strength decline was observed, mainly due to internal cracking, brucite formation, and the transformation of C–S–H into non-cementitious M–S–H gel. Based on these findings, the combined use of CS and RCA at low replacement levels shows potential for producing environmentally friendly concrete with mechanical and durability performance comparable to those of concrete made entirely with virgin materials.