Performance Evaluation of HDPE-Bakelite Dual-Modified Asphalt Mixtures for Sustainable Pavements

Flexible pavements using conventional bitumen are prone to suffering severe distress in hot climates, particularly rutting and moisture-induced damage. This study explores synergistic effects of waste-derived High-Density Polyethylene (HDPE) and Bakelite as dual modifiers for asphalt mixtures under Pakistan’s extreme climate, where summer temperatures exceed 45 °C. Modified mixtures were prepared via wet process using HDPE (3%, 6%, 9% by weight of optimum bitumen content) combined with 6% Bakelite, evaluated against control mixtures (60/70 bitumen, NHA Class-B gradation). Performance assessment included indirect tensile strength, moisture susceptibility (TSR), resilient modulus, and Hamburg wheel tracking tests. The optimal 6%HDPE + 6%Bakelite formulation achieved remarkable improvements over control: 24.7% higher dry ITS (0.647 MPa), 48.7% higher conditioned ITS (0.617 MPa), 95.36% TSR (19% above specifications), 43.7% greater resilient modulus (4866 MPa), and 27.4% lower rutting depth (2.38 mm). These enhancements are likely associated with the development of a stiffer polymer resin network between HDPE and rigid Bakelite particles, which appears to provide a favorable balance between mixture flexibility and stiffness. At 9% HDPE, performance degradation in strength and moisture-related properties suggests possible phase separation, although rutting resistance continued improving. This dual-modification strategy provides sustainable, cost-effective enhancement of pavement durability in hot climates while addressing waste management challenges, offering significant potential for reducing maintenance costs and extending service life.