Performance Evaluation of Hot Mix Asphalt Modified with Fly Ash and Waste Foundry Sand in Road Development

This research evaluates the performance of hot mix asphalt modified with fly ash and waste foundry sand for road development. Preliminary tests were conducted to determine material properties. Hot mix asphalt samples with varying percentages of granite, sand, stone dust, and bitumen (5%, 5.5%, 6%, 6.5%, and 7%) were produced using ASTM D6927 Marshall mix design. The optimum bitumen content (OBC) was found from the mix to be 5.7%. Using the same mix design, bituminous mixtures were created with waste foundry sand as a partial replacement for fine aggregate (10% - 50% at 10% intervals), along with granite, stone dust, and 5.7% bitumen (OBC). The mix with 40% replacement performed optimally. A new mixture, incorporating granite, sand, fly ash (10% - 60% replacement for filler material, at 10% intervals), and 5.7% bitumen (OBC), was produced. The optimal replacement percentage was 50%. A combination mix of the materials, based on derived optimums, achieved a stability value of 26.09 kN, meeting the Asphalt Institute's criteria. Microstructural analysis indicated a densely packed agglomeration of particles, implying good strength properties. This research demonstrates the viability of waste foundry sand and fly ash as alternative materials, enhancing the strength and flexibility of hot mix asphalt. Reusing these waste materials in road construction is a positive step towards sustainability.