Graded Utilization of Asphalt Mixing Plant Dust in Alkali-Activated Concrete Paving Blocks: Mechanical Performance and Sustainability Assessment

The large-scale generation of asphalt dust waste (ADW) has raised increasing environmental concerns, while its high-value utilization in cementitious materials remains insufficiently explored, particularly in terms of mechanical performance, durability-related properties, and integrated sustainability evaluation. In this study, a graded utilization strategy based on particle size was proposed to incorporate ADW into alkali-activated concrete paving blocks, in which fine ADW fraction (<0.075 mm) was used as a partial replacement of blast furnace slag (BFS), while the coarser ADW fraction was used as a partial replacement of river sand, aiming at sustainable pavement applications. In addition, two types of ADW with different lithologies, namely limestone ADW and basalt ADW, along with their combined system, were investigated. The results show that the incorporation of ADW effectively enhances the engineering performance of paving blocks. The compressive strength increased from 45.3 MPa to 56.6 MPa, while water absorption decreased from 5.3% to 4.1%. All mixtures satisfied the requirements for abrasion resistance and slip resistance, demonstrating their compliance with the performance criteria for pedestrian pavement applications. Among all mixtures, the combined use of limestone ADW and basalt ADW exhibited the best overall performance. The improved performance may be attributed to the combined effects of graded particle utilization and the potential compositional complementarity between calcium-rich limestone ADW and silica–alumina-rich basalt ADW, which is consistent with the denser microstructure observed in SEM images. In addition, the proposed strategy contributes to improved solid waste utilization and reduced consumption of natural resources, as reflected in the quantitative sustainability assessment. Overall, this study demonstrates that graded utilization of ADW is a feasible approach for developing alkali-activated paving materials, with promising performance and sustainability potential.