Advancing Pavement Sustainability: Assessing Recycled Aggregates as Substitutes in Hot Mix Asphalt

The integration of Recycled Concrete Aggregate (RCA) and Reclaimed Asphalt Pavement (RAP) into Hot Mix Asphalt (HMA) presents a sustainable solution to mitigate environmental impacts and reduce reliance on virgin materials. This study investigates the influence of RCA and RAP as partial replacements for natural limestone aggregates on the volumetric, mechanical, and performance properties of asphalt mixtures. Replacement levels of 11%, 33%, and 66% (by total aggregate weight) were evaluated through comprehensive testing, including dynamic modulus, flow number, stiffness factor, and loss modulus assessments under varying temperatures and loading frequencies. Findings indicate that recycled aggregate incorporation results in a progressive reduction in optimum asphalt binder content, voids in mineral aggregates (VMAs), and voids filled with asphalt (VFAs). While all mixtures demonstrated acceptable stiffness-frequency behavior, the 33% replacement mix provided the best balance of rutting resistance and fatigue performance, satisfying Superpave volumetric criteria. The 11% mix exhibited enhanced fatigue resistance, whereas the 66% mix, despite showing the highest rutting stiffness, failed to meet minimum volumetric thresholds and is therefore unsuitable for structural applications. Statistical analysis (one-way ANOVA) confirmed the significant effect of RCA and RAP content on the mechanical response across performance zones. The results highlight the potential of using moderate recycled aggregate levels (particularly 33%) to produce durable, sustainable, and cost-efficient asphalt mixtures. For regions with mixed distress conditions, a 33% replacement is recommended, while 11% may be preferable in fatigue-critical environments. Further research incorporating viscoelastic continuum damage models and life cycle cost analysis is suggested to optimize design strategies and quantify long-term benefits.