Conventional asphalt has been used along the time with relatively satisfactory performance. However better performance in terms of development, environment, and economic benefits needs to be addressed. Asphalt binder modification has been one of the most common methods to improve the performance of bitumen over time. The objective of this study is to provide insight into the modification of asphalt binders to reduce thermal cycling by introducing Aerogel. Several tests were conducted including Softening Point (SP), Rotational Viscosity (RV), Dynamic Shear Modulus (G*), Multiple Stress Creep Recovery (MSCR), Flexural Creep Stiffness (BBR), Binder Bond Strength (BBS), and Thermal Conductivity (TC) tests. The response of five aerogel products was assessed based on performance. The outcomes of this study were encouraging and promising. Thermal resistance properties and cost per kilogram of each product were used to determine the more suitable aerogel product for further utilisation. The addition of aerogel reduced the susceptibility to damaging thermal effects of bitumen, reducing the permanent deformation and thermal cracking potential. However, the implementation of aerogel in binder must be enhanced to overcome the workability and safety concerns, which restrict the feasibility of its usage.

The United States produces approximately 500 million tons of asphalt mixtures annually, while generating vast amounts of waste materials that could be repurposed for sustainable infrastructure. Each year, 1.4 billion gallons of lubricating oils are available for reuse and recycling. Additionally, 280 million tires are discarded, contributing to significant environmental challenges. Given the critical role of the roadway network in economic growth, mobility, and infrastructure sustainability, there is a pressing need for innovative material solutions that integrate recycled materials without compromising performance. This study introduces a Rubberized-Aerogel Composite (RaC), a novel asphalt binder modifier combining crumb rubber, recycled oil, and a silica-based aerogel to enhance the sustainability and durability of asphalt pavements. The research methodology involved blending the RaC with the PG70-10 asphalt binder at a 5:1 ratio and conducting comprehensive laboratory tests on binders and mixtures, including rheology, thermal conductivity (TC), specific heat capacity (Cp), the Hamburg Wheel-Tracking Test (HWTT), and indirect tensile strength (IDT). Pavement performance was simulated using AASHTOWare Pavement ME under hot and cold climates with thin and thick pavement structures. Results showed that RaC-modified binders reduced thermal conductivity by up to 30% and increased specific heat capacity by 15%, improving thermal stability. RaC mixtures exhibited a 50% reduction in rut depth in the HWTT and lower thermal expansion/contraction coefficients. Pavement ME simulations predicted up to 40% less permanent deformation and 60% reduced thermal cracking for RaC mixtures compared to the controls. RaC enhances pavement lifespan, reduces maintenance costs, and promotes environmental sustainability by repurposing waste materials, offering a scalable solution for resilient infrastructure.