Study on the Optimization of Mix Proportions for Recycled Aggregate Concrete and Its Freeze–Thaw Resistance Performance

The growing volume of construction and demolition waste has made discarded concrete a major source of urban solid waste, placing increasing pressure on land resources and the environment. Recycling waste concrete into recycled aggregate concrete (RAC) offers an effective solution for resource conservation and carbon reduction, aligning with the goals of sustainable development. However, due to the residual mortar, high porosity, and microcracks of recycled aggregates, RAC generally exhibits lower compactness, strength, and durability than conventional concrete, particularly under freeze–thaw conditions where degradation accelerates and service life decreases. To address these challenges, this study investigates the optimization of RAC mix design and its frost resistance performance for pavement base applications. An orthogonal experimental design was employed, with the water-to-binder ratio, recycled aggregate replacement ratio, and air-entraining agent dosage as key variables, while 7-day compressive strength, permeability coefficient, and rebound modulus served as evaluation indices. The influence and interaction of these factors were analyzed to determine an optimal mix meeting both mechanical and durability requirements. Rapid freeze–thaw cycling tests were then conducted to examine the variations in mass loss, relative dynamic modulus, and compressive strength retention, followed by exponential and damage variable modeling to characterize the degradation process. Results show that the water-to-binder ratio primarily governs strength, the replacement ratio affects stiffness and permeability, and the air-entraining agent significantly enhances frost resistance by improving pore structure. The optimized mix retained over 70% of its relative dynamic modulus after 300 freeze–thaw cycles, exhibiting superior durability. This work establishes a systematic framework for multi-factor optimization and durability evaluation of RAC, providing theoretical and practical guidance for its application in cold-region pavement bases.