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This research examines the application of treated recycled aggregates (TRAs) in concrete to decrease the consumption of natural aggregates, thereby promoting sustainability and improving material life cycle management. A novel two-stage mixing process is utilised, beginning with the pre-soaking of recycled aggregates in 3% acetic acid for 72 h to weaken the adhered mortar. This is succeeded by mechanical grinding using wire mesh brushes and iron balls in a drum mixer to enhance the quality of the aggregate. Experimental findings indicate that an increase in TRA replacement leads to a decline in workability, density, and durability. The slump reduces from over 75 mm at 0%–20% replacement to 50 mm at 50%–60%, and the density decreases from 2400 kg/m³ to below 2250 kg/m³. Water absorption increases from below 6% to 8%, resulting in a rise in sorptivity from 2% to 3.5%. Experimental analysis indicates that a 20% replacement of TRA and a revolution time of 20 min are optimal, resulting in a compressive strength of 50–55 MPa. Response surface analysis indicates significant effects of TRA replacement and revolution time (p-values < 0.05), demonstrating strong model reliability (R2 > 0.90, low root mean square error).

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