Waste By-Products in Asphalt Concrete Pavement Construction: A Review
Abstract
1. Introduction
2. Incorporation of Mining Wastes as Bitumen Modifiers
2.1. Bitumen
2.2. Steel Slag
2.3. Fly Ash
2.4. Silica Fume
2.5. Red Mud
2.6. Physical Properties
2.6.1. Penetration Value
2.6.2. Softening Point
2.6.3. Viscosity
2.6.4. Dynamic Shear Rheometer
2.6.5. Aging
2.7. Mechanical Properties
2.8. Chemical Properties
2.8.1. Fourier Transform Infrared Spectroscopy (FTIR)
2.8.2. Attenuated Total Reflectance (ATR)
2.8.3. Differential Scanning Calorimetry (DSC)
2.8.4. X-Ray Diffraction (XRD)
2.9. Microstructural Properties
2.9.1. Scanning Electron Microscopy
2.9.2. Field Emission Scanning Electron Microscopy
2.9.3. Mapping and Phase Profiling
2.9.4. Energy Dispersive X-Ray Analysis
2.9.5. Atomic Force Microscopy
3. Use of Mining Wastes as Fillers and Aggregates in Asphalt Mixtures
3.1. Steel Slag
3.2. Fly Ash
3.3. Silica Fume
3.4. Red Mud
3.5. Mechanical Properties
3.5.1. Rutting Resistance
3.5.2. Cracking Resistance
3.5.3. Fatigue Resistance
3.5.4. Moisture Susceptibility
3.6. Environmental and Circular Economy
4. Conclusions
- Sustainable Resource Utilization:Mining wastes, once viewed as environmentally burdensome by-products of metallurgical and mining operations, are now recognized as valuable secondary resources. Their integration into asphalt mixtures offers a promising pathway to improve pavement performance while promoting sustainable material use.
- Environmental Benefits:Utilizing these wastes as alternative fillers or aggregates reduces the dependency on virgin materials, which are typically sourced through environmentally damaging quarrying activities. This contributes to lower greenhouse gas emissions, reduced habitat destruction, and less energy consumption during material extraction and processing.
- Waste Diversion and the Circular Economy:Incorporating waste-derived materials into asphalt mixtures not only minimizes industrial waste stockpiling and landfilling but also supports closed-loop material recovery, aligning with circular economy principles.
- Pollution Mitigation:Some mining wastes, such as red mud, pose significant environmental risks due to their high alkalinity and potential for heavy metal leaching. Repurposing these materials in asphalt pavements can prevent environmental contamination and reduce the need for costly long-term storage or remediation strategies.
- Enhanced Material Performance:The inclusion of materials like steel slag and silica fume has been shown to enhance the mechanical properties of asphalt concrete, including increased stiffness, durability, and resistance to rutting and moisture damage.
5. Future Research Directions
- Standardization of Characterization and Material Processing: Consistent procedures are required for the handling and classification of mining wastes, including fly ash, steel slag, and red mud. Binder compatibility and long-term performance are impacted by differences in particle size and chemical makeup. For dependable use, future research should develop uniform pre-treatment and mixing protocols.
- Long-Term Durability and Field Validation: To date, most research has been restricted to laboratory-scale assessments. Validating laboratory results requires field testing and performance monitoring in real-world settings (such as traffic, loads, and cli-mate). It is necessary to evaluate the changed mixtures’ long-term aging, rutting, and cracking behavior over prolonged service times.
- Life Cycle Assessment (LCA) and Cost–Benefit Analysis: To measure environmental savings, more thorough LCA studies spanning various waste kinds and mix designs are required. Finding the most economical and environmentally friendly waste management techniques will be made easier by combining LCA with techno-economic analysis.
- Leaching and Environmental Safety: Leaching concerns may arise from the presence of heavy metals or alkaline chemicals in some mining wastes. To guarantee safe use, long-term environmental impact assessments are necessary, particularly in applica-tions that are porous or exposed to water.
- Optimization: Studies relating to the optimal dosage of mining wastes using optimi-zation methods have not been carried out. Hence, the development of an optimal dosage is needed to ensure optimum results for road construction as well as for in-dustrial-scale production.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Component | Red Mud | Steel Slag | Fly Ash |
---|---|---|---|
Iron Oxide | 25–30% | 15–20% | 10–15% |
Aluminum Oxide | 10–15% | 5–7% | 20–25% |
Silicone Oxide | 8–12% | 10–12% | 50–60% |
Calcium Oxide | 2–5% | 35–45% | 1–3% |
Sodium and Potassium Oxides | 4–6% | <1% | 2–4% |
Mining Wastes | Main Findings | References |
---|---|---|
Red Mud | High concentration of iron oxide contributes to increased binder stiffness, adhesion, and improved fatigue resistance, making it effective in enhancing the mechanical performance of asphalt mixtures. | [20] |
Steel Slag | High calcium oxide is beneficial for improving moisture resistance and enhancing the alkalinity of the mixture, which gives better binder adhesion. | [10] |
Fly Ash | Has the a content of aluminum oxide, which is important for pozzolanic activity and improved bonding, contributing to increased durability. Acts as strong filler material that enhances packing density and thermal stability due to high content of silicon oxide. | [5] |
Physical Property | Main Findings | References |
---|---|---|
Penetration Value | Decreased values with red mud, fly ash, and steel slag indicate increased stiffness and improved rutting resistance. | [10] |
Softening Point | Increased softening point (by 8–15 °C) due to electric arc furnace slag, copper slag, and red mud improves thermal resistance. | [14,23,32] |
Viscosity | Higher viscosity from fly ash/red mud improves coating, durability, and moisture resistance; warm mix and sulfur additives lower compaction temperatures. | [15,37,40] |
Dynamic Shear Rheometer | Mining waste additives increase G*/sinδ and improve fatigue and rutting resistance. Increased G* and decreased δ with additives indicate improved deformation resistance. | [15,39,40,41] |
Aging | Pozzolanic and antioxidant properties in red mud, fly ash, and slags mitigate oxidation and aging effects. | [42,43] |
Compound | Red Mud (%) |
---|---|
Fe2O3 | 28.4 |
Al2O3 | 17.5 |
SiO2 | 12.6 |
CaO | 4.8 |
TiO2 | 2.1 |
Na2O | 4.3 |
K2O | 1.9 |
Others | <1.0 |
Properties | Key Findings | Relevant Mining Waste | References |
---|---|---|---|
FTIR and ATR | Detected functional groups, such as –OH, C=O, and Si–OH, indicating improved interaction between mining waste and bitumen, enhancing filler–binder bonding. | Red Mud, Steel Slag, and Silica Fume | [5,38,45] |
DSC | Revealed enhanced thermal stability and altered glass transition temperatures (Tg) in modified binders, improving elasticity and temperature resistance. | Steel Slag | [12,15,46] |
XRD | Identified crystalline phases like hematite, quartz, and gibbsite, confirming increased crystallinity and physical stability in modified binders. | Red Mud and Fly Ash | [10,14,44] |
XRF | Quantified high levels of oxides (Fe2O3, Al2O3, SiO2, CaO), supporting improved stiffness, adhesion, and reduced moisture susceptibility in bitumen. | Red Mud, Fly Ash, and Steel Slag | [20,44,45] |
Technique | Key Findings | References |
---|---|---|
SEM (Scanning Electron Microscopy) | Reveals rough surface morphology and particle dispersion; red mud and steel slag enhance bonding; cohesive microstructure improves durability and resistance to rutting. | [9,20,48,52] |
FESEM (Field Emission Scanning Electron Microscopy) | Visualizes nanoscale features and confirms element dispersion; FESEM shows oxides, like Fe, Al, and Si, uniformly embedded, enhancing filler–matrix bonding. | [20,50,51] |
MAPP (Mapping and Phase Profiling) | Combines SEM with spectroscopy to analyze phase distribution; shows uniform mineral dispersion, smoother surfaces, and fewer voids, leading to better compatibility and reduced air voids. | [12,53,54] |
EDAX/EDS (Energy-Dispersive X-ray Analysis) | Identifies elemental composition, such as Ca, Si, Al, and Fe, in fillers; confirms the chemical components that enhance binder reactivity and mechanical strength. | [47] |
AFM (Atomic Force Microscopy) | Analyzes surface roughness and adhesion at the nanoscale; nanostructures improve fatigue and moisture resistance; higher elasticity and stress distribution. | [49,55,56] |
Mining Waste | Key Benefits | Performance Findings | References |
---|---|---|---|
Steel Slag | High angularity, hardness, improves rutting resistance, Marshall stability, and moisture resistance | Used as coarse and fine aggregate; BOF and EAF slags improve fatigue life and stiffness modulus | [8,23,24,57,58] |
Fly Ash | Enhances binder stiffness, improves workability and fatigue resistance, good filler replacement | Classes F and C fly ash improve water resistance; spherical particles aid mastic stiffness and packing | [10,11] |
Silica Fume | Improves fatigue and rutting resistance, promotes adhesion and filler–binder interactions | Used in hot-/cold-mix; fills micro-voids, improves cohesion and aggregate adhesion | [2,12,15] |
Red Mud (Iron Oxide) | Enhances thermal conductivity, aging and UV resistance, improves Marshall stability and high-temp performance | Requires additives to reduce fatigue life impact and voids; 3–7% inclusion improves rut depth and stability | [3,7,13,20,61,64,65] |
Technique | Key Findings | References |
---|---|---|
Rutting Resistance | Steel slag improves load distribution and shear resistance; red mud enhances high-temp stiffness; 3–7% red mud reduces rut depth | [3,7,57,66] |
Cracking Resistance | Silica fume and fly ash enhance binder flexibility and compaction; 6% silica fume reduces low-temp cracking | [10,11,12,28] |
Fatigue Resistance | Steel slag and silica fume improve fatigue life through better binder interaction; enhances resistance to cyclic loading | [2,8,23,28] |
Moisture Susceptibility | Steel slag and fly ash improve adhesion and reduce water damage; red mud needs anti-stripping agents due to porosity | [6,8,11,13,66] |
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Mashaan, N.S.; Oguntayo, D.O.; Dassanayake, C. Waste By-Products in Asphalt Concrete Pavement Construction: A Review. Materials 2025, 18, 4092. https://doi.org/10.3390/ma18174092
Mashaan NS, Oguntayo DO, Dassanayake C. Waste By-Products in Asphalt Concrete Pavement Construction: A Review. Materials. 2025; 18(17):4092. https://doi.org/10.3390/ma18174092
Chicago/Turabian StyleMashaan, Nuha S., Daniel O. Oguntayo, and Chathurika Dassanayake. 2025. "Waste By-Products in Asphalt Concrete Pavement Construction: A Review" Materials 18, no. 17: 4092. https://doi.org/10.3390/ma18174092
APA StyleMashaan, N. S., Oguntayo, D. O., & Dassanayake, C. (2025). Waste By-Products in Asphalt Concrete Pavement Construction: A Review. Materials, 18(17), 4092. https://doi.org/10.3390/ma18174092