1. Introduction
The durability and performance properties of road pavements depend greatly on the composition and microstructural characteristics of the materials used in their composition. Among them, asphalt concrete holds a dominant position due to its flexibility, simplicity of maintenance, and cost-effectiveness. However, the mining and use of natural mineral powders, such as limestone powder, resulted in many environmental and economic problems, including the exhaustion of natural resources, an increase in the carbon footprint, and a rise in construction costs. Concurrently, the accumulation of industrial waste, particularly fly ash from thermal power plants (TPPs), became a serious environmental problem. The need for a rational use of natural resources and waste recycling encouraged active research into the use of industrial by-products as alternative mineral fillers for asphalt concrete mixtures [
1,
2,
3].
Fly ash is a finely dispersed powder obtained from coal combustion at TPPs. Its physical and chemical properties are similar to those of traditional limestone powder, and it consists primarily of silicon dioxide, aluminum oxide, and iron oxide. Its high specific surface area and pozzolanic activity make it a suitable material for partially replacing natural mineral fillers in asphalt concrete. Many studies showed that fly ash can improve the workability, high-temperature stability, and longevity of asphalt mastic [
4,
5]. However, most of these studies were carried out under material, climate, and traffic conditions that differ from those in Kazakhstan.
The mineral filler in asphalt concrete mixtures, while filling the pores, significantly affects the rheological properties of the binder, the strength of grain adhesion, and the resistance to temperature and moisture. Hence, the chemical composition, morphology, and surface properties of fillers play a key role in determining the microstructure of asphalt mastic [
6]. Traditional limestone powders are highly hydrophilic [
7], which reduces adhesion at the binder–filler interface when moistened. Conversely, fly ash particles, especially after surface modification or activation, have a greater hydrophobicity and pozzolanic activity, which increases bond strength [
8]. International practice in road construction shows a broad use of fly ash and other industrial by-products. For decades, the US Federal Highway Administration (FHWA) has advocated for the use of fly ash in asphalt concrete, publishing regulatory recommendations on its properties and methods of evaluation [
8]. Researchers in Europe and Asia are actively studying the use of by-products such as steelmaking slag, waste ashes from incinerators, and glass powder as mineral fillers or fine aggregates [
9,
10]. For Kazakhstan, where a significant part of electricity is generated by coal-fired TPPs, the problem of ash disposal is of particular importance. Annually, the country generates over 20 million tons of ash, less than 10% of which is recycled [
11]. Despite this, fly ash is still not widely used as a filler in asphalt mixtures in Kazakhstan, and its behavior under local standards has been studied only fragmentarily. Such underutilization of resources creates environmental and logistical difficulties, making its involvement in the production of building materials a strategically important direction.
Back in the early 1990s, ref. [
12] showed that using fly ash in asphalt concrete helps make the mix stiffer and strengthens the binder–aggregate bond. Later, the guidelines [
8] standardized the requirements for ash used in road construction. Contemporary research develops these ideas using microstructural and rheological analysis. For example, ref. [
4] found that replacing limestone powder with fly ash increases the high-temperature stability of mastics due to the spherical shape and chemical activity of the particles. Similar conclusions were made by [
9,
13], who noted an increase in stiffness, fatigue resistance, and anti-delamination properties, although an excessive proportion of ash can reduce elasticity at low temperatures.
Recent research has focused on the chemical activation and hydrophobic modification of fillers. It has been established that treating ash with stearic acid or silane compounds increases the contact angle and reduces surface energy, which improves the water resistance of asphalt concrete [
14,
15]. Ref. [
16] showed that coal gasification ash modified with stearic acid has a better dispersibility and adhesion to bitumen, increasing its rutting resistance. Meanwhile, studies of carbonate fillers with adjustable hydrophilic–hydrophobic properties have shown the possibility of optimizing the balance between water resistance and cohesion [
17]. These results emphasize the need to consider not only the mineral composition but also the surface chemistry when designing a binder–filler system.
Studies of cement–asphalt composites have also confirmed the positive effect of fly ash on strength and durability. Ref. [
18] found that the use of fuel ash increases compressive strength and reduces permeability due to the microfiltration effect and pozzolanic reactions. Similar results were obtained when using ash from waste incineration plants as mineral powder [
19]. The use of production and processing waste is also linked to the UN Sustainable Development Goals (SDGs) 9 and 12, which target lower environmental pollution and more efficient resource use [
20].
For Kazakhstan, which has a sharply continental climate with large seasonal temperature fluctuations, the problem of thermal stresses in asphalt concrete pavements is of particular importance. Repeated freeze–thaw cycles, high summer surface temperatures, and low winter temperatures cause thermal cracking, rutting, and the loss of bearing capacity of the subgrade [
21]. The use of modified hydrophobic fillers can significantly increase the resistance of asphalt concrete to these effects. It has been shown that the hydrophobization of the filler surface reduces moisture migration and stabilizes the binder structure, increasing the service life of the pavement [
22]. Field studies confirm the need to study the long-term behavior of modified fillers. Thus, ref. [
23] investigated the thermal expansion of cement concrete pavements in the southern regions of Kazakhstan and showed the dependence of deformations on the mineral composition and thermal sensitivity of the material. These conclusions are also important for asphalt systems, where the binder–filler interaction determines the resistance to thermal fatigue and volumetric deformation.
Although substantial progress was made, issues related to the heterogeneity of ash from different sources, which affects the reproducibility of properties, and the lack of systematic studies on the combined effects of activation, dosing, and dispersion in asphalt systems remain unresolved. In Kazakhstan and similar climatic regions, there is little data on the use of fly ash from local TPPs as modified mineral powders. National standards [
24,
25] do not yet contain requirements for such materials, which creates a regulatory gap between laboratory research and practical implementation. Thus, this study addresses the gap between international work on fly ash fillers and the limited data for Kazakhstani asphalt mixtures. The study pursues three objectives: first, to characterize hydrophobized fly ash mineral powder from a local TPP with respect to national requirements for hydrophobicity, moisture, porosity, and bitumen capacity; second, to compare the density, strength, shear resistance, water resistance, rutting, and crack resistance of asphalt mixtures with fly ash and carbonate fillers at the same optimum binder content; third, to relate the powder microstructure and these indicators to mixture-scale performance and to assess whether the modified fly ash can technically replace natural carbonate filler under the studied conditions.
2. Materials and Methods
The study began with the preparation of raw materials: coarse and fine aggregate, binder, bitumen, mineral fillers, an adhesive additive, a modifier, and a reference mineral powder. Their properties are detailed in
Appendix A.
The modified mineral powder from fly ash was produced using a dry process with simultaneous hydrophobization and surface activation. The batches of ash (including dehydrated hydro-ash) were first brought to a bulk state and fed into the line, where residual moisture was removed at a drying temperature not exceeding ~100 °C. After that, the ash was dosed and jointly ground with an organo-mineral modifier based on stearic acid in a 1.5 kW laboratory ball mill MSL-50N [
26] (Research & Engineering Corporation “Mekhanobr-Tekhnika”, Saint Petersburg, Russia) with 20 mm steel balls for 2 h at 40 rpm, at a ball-to-powder mass ratio of 20:1, with an estimated mechanical energy input of approximately 7.5 kWh/kg. Calcium stearate was used as a powder hydrophobizer in the range of 0.5–1.5% by mass (with an optimum of ~1%). During co-grinding, calcium stearate softens and spreads over the ash particles. The polar carboxylate groups interact with Ca-, Fe-, and Al-rich sites on the glassy aluminosilicate surface. The long hydrocarbon chains are oriented outward into the pore space and form a thin, low-energy organic layer on the particles. As a result, the combined ash–stearate powder becomes water-repellent.
The output was a dry, free-flowing, hydrophobic mineral powder (
Figure 1). Its compliance was recorded according to [
24,
25] with control of hydrophobicity, moisture content, porosity, bitumen capacity, and grain composition. The hydrophobicity of the activated mineral powder was determined through the free flotation method in distilled water in accordance with [
24]. Around 2 g of powder was gently placed on the surface of distilled water in a 500–800 mL glass beaker filled to about 50 mm below the rim and left undisturbed for 24 h at room temperature. The powder was classified as hydrophobic if it remained floating without visible wetting or sedimentation after 24 h.
The microstructure of the powder was studied according to [
27] using scanning electron microscopy (SEM) on a Hitachi TM4000 desktop SEM (Hitachi High-Technologies Corporation, Tokyo, Japan). The powder was gently sprinkled onto conductive carbon tape mounted on aluminum stubs, sputter-coated with a thin gold layer, and examined in high-vacuum mode at an accelerating voltage of 15 kV and a working distance of 10.1 mm, with signal recording in BSE-M (back-scattered electrons, contrast by average atomic number) and Mix-M modes (mixed mode for simultaneous evaluation of relief and compositional contrast); observations were performed at magnifications of ×250 (scale bar 200 µm) and ×1.20 k (scale bar 40 µm), which provided a comparable view from the meso- to micro-level and fixation of the morphological features of the particles and their aggregation.
The selection of asphalt concrete mix compositions was carried out in accordance with [
28]. All mixes were designed for dense fine-grained asphalt concrete Type B, Class II [
28]. The mineral part of the mixes was adjusted as fractions by weight as follows: 20% for the 10–20 mm crushed stone; 30% for the 5–20 mm crushed stone; 45% for the sand from crushed stone screenings; 5% for the mineral powders. Asphalt concrete mixtures were prepared by weighing and heating the components, followed by mixing in a laboratory paddle mixer until homogeneity was achieved. The liquid activator AMDOR-AMP at a dose of 0.2–1.0% by mass (with an optimum of ~0.3%) was added to the bitumen at a temperature of 150 °C, followed by mixing for 10–15 min for fine-tuning the properties. The optimum bitumen content was determined to be 5.2%, including the activator. Three types of mixes were prepared at temperatures ranging from 150 to 155 °C, including the following:
- (1)
A reference mix based on activated mineral powder from the “Tutas” LLP (Temirtau town, Karaganda region, Kazakhstan)—hereinafter referred to as M-R;
- (2)
The mix based on dry fly ash and stearic acid hydrophobizer—hereinafter referred to as M-DFA;
- (3)
The mix based on dehydrated hydro-ash—hereinafter referred to as M-HA.
Cylinder samples (
Figure 2) were made from the mixtures and subjected to testing according to [
29] for average density, compressive strength at 0, 20, and 50 °C, shear resistance (coefficient of internal friction and adhesion), water resistance (long-term and short-term saturation), crack resistance under tensile stress, and resistance to rutting (average rut depth). For each mixture and test type, three parallel cylindrical specimens were tested; the reported values are means of these replicates, with standard deviations (SDs) reflected as error bars.
4. Discussion
The SEM evidence shows that the fly ash mineral powder prepared through dry co-milling with a stearate modifier forms a hierarchically textured surface, in particular, cenospheres and broken shells partially armored by adherent micro- and submicron fines, which increases the effective specific surface and micromechanical interlock at the binder–filler interface. Such morphology is consistent with previous observations for fly ash fillers [
4,
8,
12]. The compliance results substantiate this. Thus, the moisture and porosity met the standards of [
24], and the material was hydrophobic; only the bitumen capacity (75% versus the 80% benchmark) fell slightly short. In practice, bitumen capacity is a proxy for the balance between the surface area/chemistry and the pore structure. The values marginally below the target do not preclude good performance if adhesion and film continuity are strong, which is what our mixture-level tests indicate [
4,
19]. Mechanistically, a slightly lower bitumen capacity for a hydrophobized, hierarchically textured powder can be beneficial: for a given total binder content (5.2 wt.% including activator), a smaller fraction of binder is immobilized within the filler porosity, and a larger fraction remains in the continuous mastic film and at aggregate contacts. This interpretation is consistent with the higher adhesion, compressive strength, and water resistance indices measured for the fly ash mixes, suggesting that the modified filler reduces the binder demand while maintaining or improving the efficiency of the binder–filler and binder–aggregate interactions. Hydrophobization by stearic acid is a plausible factor in the observed durability. The hydrophobicity test was carried out on the modified mineral powder (ash plus stearate) before mixing with bitumen. Thus, the measured water repellency reflects the surface-engineered filler rather than only the presence of stearate in the mastic. The powder passed the hydrophobicity test and had a low moisture content (
Table 1). Both fly ash mixes showed higher adhesion and water resistance indices than the reference, in line with reports that stearic acid lowers the surface energy and increases the contact angle on ash particles [
14]. Surface energy and contact angles were not measured directly in this study. The closely related work on carbonate fillers with tunable hydrophilic–hydrophobic balance also links surface chemistry to the water resistance and cohesion of asphalt systems [
15].
The strength data reveal a clear hierarchy: M-HA performs best, M-DFA is medium, and M-R is worst across 0/20/50 °C, while the average density changed negligibly. This decoupling of strength from density implies a microstructural cause rather than compaction effects—namely, a better interphase bonding and a more efficient mastic skeleton, as also observed when limestone powder is replaced by fly ash in mastic-scale rheology [
4] and in mixture studies employing industrial by-products [
9,
19]. The hydro-ash powder (M-HA) delivered the largest compressive gains at all temperatures; one explanation is that hydro-ash, after dewatering and co-milling, retains more intact plerospheres and dense fragments that, together with the fine crust seen in SEM, build a stiffer, better load-transferring skeleton. The slightly lower internal friction observed for ash mixes (0.95 → 0.94 → 0.92) is consistent with the smoother intergranular slip due to rounder particles and fine infill, but the values remain high, and adhesion increases substantially (most for M-DFA). This combination (high adhesion, minimally reduced friction) is the classic recipe for enhancing strength without sacrificing shear stability [
4,
8], which aligns with our compressive trends and with the improved crack resistance for M-DFA.
The water-related performance follows the same interfacial logic. Despite a slightly higher water saturation for ash mixes, M-DFA sustained the highest water resistance index at both 14 and 30 days, and M-HA “matured” to the reference level by day 30. These trends are consistent with the literature showing that moisture susceptibility depends more on surface energy-related interactions than on bulk saturation and that hydrophobic treatments on fly ash improve the stripping resistance [
8,
14]. The BSE-visible compositional heterogeneity (brighter Ca/Fe-richer microdomains in a darker Si-Al glass) is typical for coal fly ash. It may provide additional sites for interaction with stearate and the polar components of bitumen, which could contribute to the resistance to stripping [
1,
14]; this possible mechanism, however, was not quantified directly in the present study. These factors explain why high water resistance indices co-exist with moderate water saturation in our data and why the performance improved relative to the carbonate reference, whose hydrophilicity is well documented [
15]. Overall, these microstructural interpretations should be regarded as qualitative and based solely on SEM morphology; more detailed confirmation using, for example, EDS mapping or surface energy measurements lies beyond the scope of this work.
The rutting performance remained essentially unchanged (5.5–5.7 mm) for all mixes under the selected protocol, which agrees with studies where replacing the filler with spherical fly ash does not penalize high-temperature stability, provided that the mastic gradation remains dense and the binder content is optimized [
4,
9]. By contrast, crack resistance showed a clear ranking (M-DFA > M-HA > M-R). The superior cracking response of M-DFA, despite its lower compressive strength than M-HA, shows that stiffness alone does not control splitting tensile behavior. The higher adhesion measured for M-DFA (
Figure 5) probably contributes to its crack resistance. The fracture energy was not measured and is mentioned only as a possible factor. Similar trade-offs (where certain by-product fillers maximize fatigue or fracture resistance without maximizing stiffness) have been noted for amorphous carbon and MSWI fly ash systems [
13,
19]. In a cold-region context with large thermal swings and freeze–thaw cycling, the observed combination (unchanged rutting, higher strength, improved adhesion, and robust water resistance) addresses the principal pavement distresses expected in Kazakhstan [
6,
21,
23].
From a practical standpoint, our results show that substituting natural carbonate powder with hydrophobized fly ash maintains rutting resistance while improving strength, adhesion, and water resistance under the studied conditions. This extends earlier evidence on fly ash-extended asphalt mixtures [
12] by demonstrating that surface-engineered ash from a Kazakhstani TPP can deliver multi-property improvements without densification or an increased binder content. However, this study has several limitations. First, the fly ash came from a single Kazakhstani TPP, and its composition and loss on ignition were limited to the ranges shown in
Table A4 and
Table A5. Fly ash from other plants or with a higher unburned carbon content may behave differently. Second, the mixtures were tested under one set of laboratory protocols for a single dense, fine-graded asphalt concrete type. Third, we evaluated only technical performance; cost, carbon footprint, and life-cycle effects were not analyzed. Fourth, we investigated only the co-milled ash–stearate powder and did not include a control case where fly ash and stearate were milled separately and then blended as a filler. Fifth, moisture damage resistance was assessed using water resistance indices and water saturation according to [
29], but no dedicated anti-stripping test (such as the tensile strength ratio or boiling test) was performed. The future work should (i) quantify surface energy parameters and contact angles to directly link hydrophobization to tensile strength ratio and to type metrics; (ii) couple SEM with EDS mapping to attribute BSE contrast to phase chemistry; (iii) perform mastic-scale rheology and fracture energy tests to resolve why M-DFA leads in cracking resistance while M-HA leads in compressive strength; (iv) validate field performance over seasonal cycles and traffic loading representative of local climates; (v) compare co-milled ash–stearate powder with systems where fly ash and stearate are milled separately and blended, to separate the effect of surface engineering from the mere presence of stearate in the mixture; (vi) include standardized anti-stripping tests (e.g., tensile strength ratio or boiling tests) to quantify moisture damage resistance more directly. Overall, the convergence between microstructure, physicochemical compliance, and mixture-level properties observed here supports hydrophobic fly ash mineral powder as a technically viable and potentially resource-efficient filler for asphalt mixtures. These performance advantages should be regarded as comparative trends under the specific laboratory conditions of this study. The sustainability-related benefits discussed here are qualitative; quantitative estimates of material savings and CO
2 reduction will require a dedicated life-cycle assessment.
5. Conclusions
The hydrophobized fly ash mineral powder met the specified limits for hydrophobicity, moisture, and porosity and preserved a stable cenosphere-based morphology with adherent fines. The bitumen capacity was slightly below the benchmark, but did not prevent a good performance in the mixtures. Asphalt mixtures with the dry and hydro-activated fly ash fillers had a similar density and rutting resistance to the reference mixture with a carbonate filler. At the same optimum binder content, both fly ash mixes showed a higher strength, better adhesion, and improved indices of moisture and cracking resistance. These trends indicate that, under the tested conditions, surface-engineered fly ash from the studied source can technically replace natural carbonate filler in dense fine-graded asphalt concrete without penalties to high-temperature stability. The conclusions are limited to one fly ash source, a single mixture type, and the applied laboratory protocols, and they do not include economic or life-cycle analyses. Therefore, the sustainability benefits are discussed qualitatively and are not quantified in terms of material savings or CO2 emissions. Future work should extend testing to other fly ash sources and mixture types, include direct measurements of surface energy and fracture-related properties, and verify field performance and life-cycle impacts under real traffic and climate conditions. Thus, our conclusions refer only to the comparative behavior of the tested mixtures within this experimental framework.