Role of mineral filler type and ratio in the rheological, fatigue, and adhesive performance of asphalt mastics

• The effects of filler type and filler-to-asphalt ratio on asphalt mastic performance were systematically evaluated. • Rutting resistance, fatigue behavior, and adhesive performance were assessed using MSCR, LAS, and blister tests. • Hydrated lime significantly enhanced rutting resistance and bond strength but adversely affected fatigue durability at high dosages. • Portland cement and limestone exhibited optimal performance at intermediate filler-to-asphalt ratios (0.6 – 0.8). • Grey Decision Theory identified Portland cement at a 0.8 filler-to-asphalt ratio as the optimal mastic formulation. Mineral fillers are a fundamental component of asphalt mastic and play a critical role in governing the mechanical performance and durability of flexible pavements. Variations in filler type and dosage can substantially alter mastic stiffness, deformation resistance, fatigue behavior, and adhesion. The objective of this study is to systematically evaluate the influence of mineral filler type and filler-to-asphalt (F/A) ratio on the rheological, fatigue, and adhesive performance of asphalt mastics. Three commonly used fillers; limestone dust, Portland cement, and hydrated lime were investigated at four F/A ratios (0.6, 0.8, 1.0, and 1.2). A comprehensive experimental program was conducted, including conventional binder characterization, Multiple Stress Creep Recovery (MSCR) testing for rutting resistance, Linear Amplitude Sweep (LAS) testing for fatigue performance, and the Blister Method for adhesive bond strength evaluation. Volumetric analysis and scanning electron microscopy (SEM) were employed to support interpretation of filler packing behavior and particle morphology. Statistical analysis using two-way analysis of variance (ANOVA) confirmed that both filler type and filler content significantly influence all evaluated performance indicators. Hydrated lime markedly improved rutting resistance and bond strength but caused severe reductions in fatigue life at higher dosages due to excessive stiffness. In contrast, Portland cement and limestone provided more balanced performance, particularly at intermediate F/A ratios. A Grey Decision Theory (GDT) analysis integrating permanent strain, fatigue life, and bond strength identified the Portland cement mastic at an F/A ratio of 0.8 as the optimal formulation. Future studies are recommended to extend this approach to different binder grades, polymer-modified asphalts, and environmental conditions to further generalize the findings and support performance-based mastic design.