Laboratory Studies to Examine the Properties of a Novel Cold-Asphalt Concrete Binder Course Mixture Containing Binary Blended Cementitious Filler

Conventional hot-asphalt mixtures have an impact on global warming and CO2 emissions, contributing to debates on environmental issues that have been raised in recent years. As an alternative, cold-emulsion asphalt mixtures (CBEMs) provide considerable benefits such as eco-friendliness, energy efficiency, and cost-effectiveness connected with safety. However, their weak early strength along with the need for longer curing times (usually 2–24 months) and higher moisture susceptibility compared to hot-asphalt mixtures have been cited as obstacles to their wider application. That said, the incorporation of waste materials in CBEM mixtures enhances sustainability by decreasing the amount of industrial waste materials needed and conserving natural resources. A new binary blended cement filler (BBCF) material generated from high-calcium fly ash (HCFA) and fluid catalytic cracking catalyst (FC3R) was found to be very effective in providing microstructural integrity with a novel fast-curing cold-asphalt concrete for the binder course (CACB) mixture. Laboratory performance tests included the stiffness modulus test by indirect tension to cylindrical samples, wheel-tracking tests, and water sensitivity. Regarding environmental issues, a toxicity characteristic leaching procedure (TCLP) test was performed to analyze the leachate from various specimens in terms of their concentrations of heavy metals. The findings of these tests have demonstrated that CACB performs extremely well compared to traditional hot mixtures. The stiffness modulus of the BBCF-treated mixture—3,730 MPa after 3 days—is higher than the traditional hot mixture [100/150 penetration (pen)]. In addition, the BBCF-treated mixture offered a superior performance regarding rutting resistance, fatigue resistance, and water susceptibility, as well as revealing a considerably lower thermal sensitivity. More significantly, the BBCF-treated mixture was found comparable to the traditional asphalt concrete binder course after a very short curing time (1 day). Finally, the concentration of heavy metals in the specimens incorporating the BBCF was observed to be less than the regulatory levels determined for hazardous materials and so requirements were satisfied. Consequently, this BBCF-treated mixture has significant potential with reference to its application as a binder course in asphalt pavement.