Characterization of binder and asphalt mixture modified with waste toner

Incorporating waste materials as additives in road and highway construction offers significant economic and environmental advantages. This study utilizes waste toner (WT) as an additive in binder and asphalt mixture at varying percentages (0, 5, 10, 15, 20%) of the binder's volume. Standard asphalt binder tests such as penetration, ductility, softening point, flash and fire point, and specific gravity are conducted. Additionally, Superpave performance grading (PG) tests are carried out, including Rotational Viscosity (RV), Rolling Thin-Film Oven (RTFO), Pressure Aging Vessel (PAV), Dynamic Shear Rheometer (DSR), and Bending Beam Rheometer (BBR). Modified asphalt mixtures undergo tests for Marshall stability and flow, dynamic creep, and fatigue (indirect tensile modulus test). Results reveal that an increase in WT content affects key characteristics. Penetration and ductility decrease, while specific gravity, softening point, flash point, fire point, and RV increase. The DSR test indicates an enhancement in rutting resistance for asphalt-WT binders. Moreover, the dynamic creep test demonstrates an increase in resilient modulus and creep stiffness compared to conventional asphalt mixtures, resulting in a reduction in cumulative strain and permanent rutting values. The fatigue test shows an improvement in pavement life, thanks to higher resilient modulus values and reduction in total horizontal recoverable deformation, enhancing fatigue cracking resistance in the modified asphalt mixture. The Performance Grading (PG) of the asphalt binder with 5% and 10% WT is 82–22. Also, the final PG of the asphalt binder with 15% and 20% WT content is 82–16, which is suitable for use in high-temperature regions. Therefore, incorporating an appropriate amount of WT into binder significantly enhances road pavement performance, especially in high-temperature regions. Additionally, this research offers a promising alternative recycling approach for WT, leading to substantial environmental benefits. Thus, the process can be deemed both feasible and viable.