Fabrication of Core–Shell Aggregates from Reclaimed Asphalt Pavement (RAP): A Modification Strategy for Tailoring Structural and Surface Properties

This study presents a modification strategy to fabricate core–shell composite aggregates from reclaimed asphalt pavement (RAP), aligning with green chemistry principles for waste valorization. The method involves creating a porous cementitious shell on the surface of RAP particles through a controlled hydration process. This surface modification simultaneously addresses the inherent structural weaknesses and irregular morphology of raw RAP, enabling the design of materials with desired properties. A face-centered central composite design (FCCD) was employed to optimize the synthesis process, elucidating the nonlinear relationships between key synthesis parameters and the final material characteristics. The optimized synthesis yielded porous aggregates with significantly enhanced structural integrity, evidenced by a 43.9% reduction in crushing value. Furthermore, the surface modification effectively regulated the material’s morphology and particle size distribution, leading to a 3.6 mm increase in median particle size (D₅₀) and a 27.69% decrease in the content of fines (<4.75 mm). Microstructural characterization confirmed the formation of a rough, porous cementitious shell composed of hydration products, which provides the structural basis for the material’s enhanced performance. This work establishes a clear structure–property relationship, demonstrating a new pathway for the rational design and synthesis of functional porous materials from solid waste for application in high-grade pavements.