Research on the Performance of Ultra-High-Content Recycled Asphalt Mixture Based on Fine Separation Technology

To facilitate the high-value utilization of reclaimed asphalt pavement (RAP), this study investigated the efficacy of fine separation technology as a pre-treatment method. This technology significantly reduced the variability of RAP, controlling the coefficients of variation for asphalt content and aggregate gradation within 5% and 10%, respectively, and minimized false particle content (agglomerates of fines and aged asphalt). Response Surface Methodology (RSM) was employed to optimize the mix design for ultra-high-RAP- content mixtures (50–70%). A predictive regression model was developed to determine the Optimal Binder Content (OBC) based on RAP and rejuvenator dosage. The road performance of the resulting mixtures was comprehensively evaluated. Results showed that the technology markedly enhanced the overall performance of recycled asphalt mixtures. While high-temperature rutting resistance improved with increasing RAP content, low-temperature performance declined. The mixture with 70% RAP failed to meet low-temperature cracking requirements. Consequently, an optimal RAP content of 60% is recommended. Furthermore, the generalized sigmoidal model effectively constructed dynamic modulus master curves, accurately predicting the viscoelastic behavior of these ultra-high-RAP mixtures. This study demonstrates that fine separation is a critical pre-processing step for reliably producing high-quality, sustainable asphalt mixtures with RAP content far exceeding conventional limits.