Toward Smart Pavements: Mechanical and Volumetric Evaluation of Carbon Fiber-Reinforced Asphalt Composite

Asphalt pavements are frequently subjected to fatigue cracking, rutting, and surface wear, which accelerate maintenance needs and shorten service life. This study evaluates the performance enhancement of NHA Class B dense-graded asphalt mixtures (12.5 mm NMAS) prepared with a 60/70 penetration grade binder through carbon fiber (CF) reinforcement. Chopped fibers (~12.7 mm) were incorporated via the dry mixing process at dosages of 0.5%, 1.0%, and 1.5% by binder weight. The results indicate that the 1.0% CF mixture delivered optimal performance, with ITS increasing by 51.9%, Marshall stability improving by 38.4%, resilient modulus rising by 42.6%, and rut depth decreasing by 69.2% compared to the unmodified control. Dynamic stability reached 33,750 passes/mm, demonstrating substantial resistance to permanent deformation. Statistical analysis using one-way ANOVA confirmed that all improvements were significant (p < 0.05). Despite a ~6.7% increase in initial cost, the CF-modified mix exhibited strong economic viability, achieving a benefit–cost ratio of 4.79 and significant life-cycle savings over 20 years. These findings underscore carbon fiber as an effective modifier for developing durable, high-performance asphalt composites with reduced maintenance requirements. This work contributes to the advancement of smart and sustainable pavement technologies for resilient transportation infrastructure.