Asphalt mixture is the most widely used material in road construction, and the industry is developing more sustainable technologies. Warm mix asphalt (WMA) is a promising alternative as it saves energy, reduces fuel consumption and generates fewer gas and fume emissions, while maintaining a similar performance to hot mix asphalt (HMA). This paper presents an evaluation of the gas emissions at laboratory scale, as well as the energy consumption and production costs, of five types of WMA with the addition of natural zeolite. The control mixture was a HMA manufactured at 155 °C. The mixtures evaluated were two WMA manufactured at 135 °C with 0.3% and 0.6% natural zeolite, and three WMA with partial replacement of raw materials by 10%, 20% and 30% of reclaimed asphalt pavement (RAP); these mixtures, called WMA–RAP, were manufactured at 125 °C, 135 °C and 145 °C, respectively. The results indicated that all the mixtures evaluated reduced CO and CO₂ emissions by 2–6% and 17–37%, respectively. The energy consumption presented a 13% decrease. In the current situation, the production costs for WMA with 0.3 and 0.6% natural zeolite are slightly higher than the control mixture, because the saving achieved in fuel consumption is lower than the current cost of the additive. On the other hand, WMA manufactured with the addition of natural zeolite and RAP could produce cost savings of up to 25%, depending on the amounts of RAP and natural zeolite used.

Conventional asphalt mixtures used for road paving require high manufacturing temperatures and therefore high energy expenditure, which has a negative environmental impact and creates risk in the workplace owing to high emissions of pollutants, greenhouse gases, and toxic fumes. Reducing energy consumption and emissions is a continuous challenge for the asphalt industry. Previous studies have focused on the reduction of emissions without characterizing their composition, and detailed characterization of volatile organic compounds (VOCs) and semi-volatile organic compounds (SVOCs) in asphalt fumes is scarce. This communication describes the characterization and evaluation of VOCs and SVOCs from asphalt mixtures prepared at lower production temperatures using natural zeolite; in some cases, reclaimed asphalt pavement (RAP) was used. Fumes were extracted from different asphalt mix preparations using a gas syringe and then injected into hermetic gas sample bags. The compounds present in the fumes were sampled with a fiber and analyzed by gas-liquid chromatography coupled to mass spectrometry (GC/MS). In general, the preparation of warm mix asphalts (WMA) using RAP and natural zeolite as aggregates showed beneficial effects, reducing VOCs and SVOCs compared to hot mix asphalts (HMA). The fumes captured presented a similar composition to those from HMA, consisting principally of saturated and unsaturated aliphatic hydrocarbons and aromatic compounds but with few halogenated compounds and no polycyclic aromatic hydrocarbons. Thus, the paving mixtures described here are a friendlier alternative for the environment and for the health of road workers, in addition to permitting the re-use of RAP.