Analysis Engineering Material Feasibility of RAP & RAS Modified Hot Mix Asphalt for Bahadurganj–Araria Section of NH-327E

The use of reclaimed asphalt pavement (RAP) and recycled asphalt shingles (RAS) can support material circularity in highway construction by returning aged aggregate and binder to productive use. This study evaluates the resource-substitution potential and engineering feasibility of a dense-graded hot mix asphalt containing a combined 31.53% RAP and tear-off RAS. The mixture incorporated 19.89% virgin 13.2 mm aggregate, 43.66% virgin 6 mm aggregate, 1.94% hydrated lime, 2.48% VG-30 virgin bitumen, and 0.50% rejuvenator. A material-flow assessment was combined with gradation compliance and Marshall design results. Recycled binder supplied 3.33 percentage points of the 5.80% total binder content, corresponding to 57.4% of the binder system; RAS alone supplied 1.88 percentage points. All sieve results remained within the adopted Ministry of Road Transport and Highways limits. At the selected 5.8% binder content, the mixture achieved 1232.70 kg Marshall stability, 3.27 mm flow, bulk specific gravity of 2.443, 3.99% air voids, 14.19% VMA, and 71.89% VFB. These results demonstrate that substantial recycled-material and recycled-binder contributions can be achieved without losing basic Marshall and volumetric compliance. The design offers a technically credible pathway for reducing dependence on virgin pavement materials. However, project-specific cost, energy, emissions, leaching, durability, and field-performance data are required before claiming quantified environmental or economic benefits.