This study develops and evaluates clay–concrete hybrid materials through an integrated process design approach that aligns mechanical performance, durability behavior, environmental impact, and economic feasibility for U.S. infrastructure applications. Kaolinite-rich and montmorillonite-rich clays were thermally activated and incorporated as partial cement replacements at 10, 20, and 30 percent by mass. The mixtures were assessed using ASTM methods for compressive strength, chloride permeability, freeze–thaw durability, and surface scaling, supported by microstructural and pore-size analyses. The results show that kaolinite mixtures at 20 and 30 percent replacement maintain strength comparable to or slightly below the control and exhibit significant reductions in chloride diffusion and freeze–thaw mass loss. Montmorillonite mixtures provide moderate improvements in durability but require higher admixture dosage to achieve workable rheology. Life-cycle assessment demonstrates up to a 22 percent reduction in embodied carbon for kaolinite mixtures, while economic analysis shows material cost savings of up to fifteen dollars per cubic meter. A multi-objective optimization framework integrating strength, durability, emissions, and cost identifies kaolinite mixtures in the 20 to 30 percent range as the most efficient tradeoff solutions for U.S. infrastructure performance requirements. These findings establish calcined clay systems, particularly kaolinite-rich blends, as viable low-carbon, cost-effective alternatives to conventional Portland cement concretes and provide a process design pathway for their large-scale implementation.