Asphalt–rubber binders (A-RBs) have a long and deep history of use; however, little is known regarding the interrelated chemical behaviors and miscibility of rubber with the asphalt fractions [saturates, aromatics, resins, and asphaltenes (SARA)]. This study comprehensively attempted to address this knowledge deficiency by employing Fourier transform infrared spectroscopy (FTIR) to investigate the chemical evolution of A-RBs. A-RB interacted at 190 °C and 3000 min⁻¹ for 8 h was deemed to have the optimal rheological performance. FTIR of the liquid fractions of A-RB 190–3000 showed a prominent chemical shift in the SARA fractions, with new peaks that showed rubber polybutadiene (PB) and polystyrene migration into asphaltenes. Meanwhile, decreases in peaks with C–H aromatic bending and S=O stretching for the A-RB 190–3000 saturates showed that the rubber absorbed low-molecular-weight maltenes during swelling. Peaks associated with C=C aromatic appeared in saturates and aromatics, respectively, emphasizing that unsaturated components migrated from the rubber into the asphalt. Thermal analysis showed that rubber dissolution for this sample reached 82%. While a PB peak existed in asphaltenes of A-RB 220–3000, its intensity was diminished by depolymerization, thus compromising the integrity of the migrated rubber structure and generating less rheological enhancement. This study concludes that FTIR characterization of SARA fractions offers valuable insights into the interactions between asphalt and rubber, and that regulated processing conditions are essential for enhancing binder performance.

High Friction Surface Treatments (HFSTs) are frequently used to increase skid resistance and reduce collisions, particularly in crash-prone zones, including horizontal curves and intersections. Epoxy-based binders traditionally have been the sole option for HFSTs, but their drawbacks, such as high costs and compatibility challenges, have led to the search for substitute binders, including asphalt-based options. This study investigates the comparative performance of highly modified asphalt-based binders, including polymer-modified, mastic, and highly modified emulsions, in HFST applications using two aggregate types, Calcined Bauxite (CB) and Rhyolite with different gradations, with an emphasis on their frictional properties, durability, and resistance to polishing. Laboratory evaluations, including the Pendulum Tester (BPT), Dynamic Friction Testing Equipment (DFT), Surface Texture Measurement Apparatus (CTM), and Binder Bond Strength Test (BBS), were carried out to examine the Coefficient of Friction (COF), Mean Profile Depth (MPD), and aggregate bonding and retention. In terms of durability and friction, this study indicated that highly modified asphalt-based binders performed better than PG binders and conventional emulsions. The highest BPT values, both prior to and following polishing, were consistently observed for CB, with the emulsion containing the highest reactive polymer modifier showing the smallest decrease in BPT value (12.86% for CB and 10.34% for Rhyolite). Epoxy showed a greater COF retention over lengthy polishing cycles; however, highly polymer-modified (PM) binders like PG82-22 (PM) performed better than Epoxy under specific conditions. The macrotexture analysis revealed that Epoxy-based samples retained surface texture for further polishing cycles, while Mastic2 and PG82-22 (PM) also showed strong MPD retention. These findings highlight the importance of optimizing aggregate–binder combinations to ensure durable and effective HFST applications.

Road deterioration inspires researchers to enhance the properties of asphalt binder for better performing mixes. Recycled tire rubber, or crumb rubber modifier (CRM), and used motor oil (UMO) are two modifiers that enhance asphalt binder performance through two different mechanisms. CRM affects high-temperature properties while UMO modifies low-temperature properties. Potential environmental concerns arising from the use of UMO have been raised in the literature. In this paper, the two recycled materials were investigated for their ability to complement each other. Both performance benefits of using both materials and the environmental concerns of using UMO were studied. Four CRM asphalt binders were investigated: two with UMO and two without UMO. Environmental impacts were evaluated using gas chromatography to check air emissions for benzene, toluene, ethyl-benzene, and xylenes (BTEX). The potential for toxic leaching of elements from modified hot mix asphalt (HMA) were checked using the US Environmental Protection Agency (EPA) Toxicity Characteristic Leaching Protocol (TCLP). For asphalt binders modified by CRM-UMO combinations, CRM decreased the amounts of released BTEX components, presumably by absorbing UMO and slowing the release of BTEX. Leaching results concluded that UMO mixtures showed a notable percentage of sulfur (S) as compared to non-UMO mixes. All these leachate components were under EPA limits.

The relation between the molecular attributes of crumb rubber–modified asphalt (CRMA) fractions and the enhancement in the CRMA in-service properties was investigated. This was achieved by investigating the relation between the enhancement of the CRMA physical properties expressed in terms of its stiffness (complex modulus [G*]) and elasticity (phase angle [δ]) and the change in its molecular structure. Gel permeation chromatography analysis on the liquid phase of CRMA fractions was employed to characterize the change in the CRMA fractions (saturates, asphaltenes, naphthene aromatics, and polar aromatics). Research results showed that, for most of the samples, there is a marked difference in the weight average molecular weight and polydispersity index in relation to enhancement of the physical properties. This indicates that the crumb rubber–modified components played a role in the change of the internal structure of the CRMA, leading to enhancement in its physical properties and thus its expected in-service performance.

Understanding the development of an asphalt binder’s internal network structure is essential when interacting asphalt and crumb rubber. Thus, the focus of this study was to reveal the development of asphalt–rubber binders’ (A-RBs) network structures at different interaction times and their correlation with performance. Atomic force microscopy (AFM) was utilized to image the morphologies of the binders, and the binders’ performances were explored rheologically with a dynamic shear rheometer. Extending the interaction time to 8 h and utilizing a soft binder altered the network structures from agglomerated dispersoids—minuscule distributed phase zones embedded in the continuous matrix of the asphalt binder—to well-organized lamellar structures. At 8 h, using a softer binder increased stiffness by 25% and elasticity by 15%, accelerating early rubber dissolution. Extending the interaction time from 4 to 8 h increased rubber dissolution by 5–23%, depending on the binder type. The 150% increase in stress overshoot for A-RBs with the soft binder versus those with the stiff one reflects the development of the network structure. At 8 h, the soft binder reduced the AFM mean phase angle by 10% and the standard deviation by 64%, indicating a more homogeneous and stable network than that obtained with the stiff binder. Thus, the 8 h interaction time and soft binder facilitated rubber swelling and enhanced component diffusion, aiding in the formation of a homogeneous network.