Development of Low Rolling Resistance Asphalt Mixtures with RAP and WMA Technologies

The development of sustainable and energy-efficient asphalt pavements is essential to address the growing demand for climate-neutral transportation infrastructure. This study investigates the structural design and functional performance of low rolling resistance asphalt mixtures utilizing reclaimed asphalt pavement (RAP) and warm mix asphalt (WMA) technologies. Ten mixtures with WMA additive—including asphalt concrete (AC) and stone mastic asphalt (SMA) with and without RAP—were evaluated for volumetric and mechanical performance. Laboratory results show that RAP addition did not compromise compaction nor indirect tensile strength ratio (ITSR), and in some cases improved these properties. SMA and SMA RAP-modified mixtures achieved the highest resistance to rutting (as low as 5.0% rut depth), while AC and SMA mixtures both demonstrated low rolling resistance (coefficients of energy loss 0.00604–0.00636). Resistance to low-temperature cracking was strong for all mixtures, with thermal stress restrained specimen test (TSRST) fracture temperatures ranging from −32.8 °C to −36.0 °C. SMA mixtures generally exhibited superior resistance to fatigue (up to 63 με at 1 million cycles). Overall, three asphalt mixtures with different particle size distribution containing 14% RAP and a WMA additive (SMA 8 S_1 R, SMA 8 S_3 R, and AC 11 VS_2 R) demonstrated the best balance of rolling resistance, durability, and circularity, and are recommended for field trials to support climate-neutral and sustainable road infrastructure. These results encourage broader adoption of circular practices in road infrastructure projects, contributing to lower emissions and life-cycle costs.