Durability and Multi-Scale Deterioration Mechanism of Cast-In Situ Iron Ore Tailings Concrete Under Complex Multi-Ion Corrosion

To investigate the corrosion resistance and deterioration mechanism of cast-in situ concrete incorporating iron ore tailings aggregate (IOT), specimens with IOT replacement ratios of 0%, 30%, and 50% were exposed to distilled water, endogenous Cl−-SO42− corrosion, exogenous Mg2+-SO42− corrosion, and endogenous-exogenous coupled corrosion. The evolution of mass, size, compressive strength, and flexural strength was evaluated, while Nuclear Magnetic Resonance (NMR), Scanning Electron Microscope-Energy Dispersive Spectroscopy (SEM-EDS), X-ray Diffraction (XRD), and Thermogravimetric Analysis/Derivative Thermogravimetry (TG/DTG) were used to characterize pore structure and phase transformation. Results show that distilled water causes limited variation, whereas exogenous and coupled corrosion accelerate product accumulation, size expansion, pore coarsening, and strength degradation. Under exogenous Mg2+-SO42− corrosion, the peak compressive strengths of specimens with 0%, 30%, and 50% IOT reach 43.30 MPa, 45.60 MPa, and 46.93 MPa, respectively, with the 50% IOT specimen showing an 8.38% increase compared with the specimen without IOT. TG/DTG results show that the Ca(OH)2 related mass loss decreases from 5.42% under distilled water immersion to 4.37% under exogenous Mg2+-SO42− corrosion, confirming calcium consumption during sulfate–magnesium attack. Microstructural characterization reveals that sulfate reaction, chloride binding, and Mg2+-induced decalcification jointly promote the formation of gypsum, ettringite, Friedel’s salt, magnesium silicate hydrate (M-S-H), and magnesium-associated corrosion products. Overall, 30% IOT provides better pore refinement and mechanical stability under endogenous and exogenous corrosion, whereas 50% IOT improves residual skeleton support under coupled corrosion. These findings provide guidance for durability design and sustainable utilization of IOT aggregate in cast-in situ concrete.