Replacing natural fillers with industrial by-products can enhance pavement sustainability by conserving resources and reducing environmental impact. This study evaluated steel slag as a filler replacement ranging from 0 % to 100 % in asphalt mastics and micro-surfacing. Surface free energy analysis linked the slag’s mineralogical and morphological features to improved binder–filler adhesion. Mechanical performance was assessed via wet track abrasion, cohesion, and loaded wheel tests. Safety and sustainability were examined using the Toxicity Characteristic Leaching Procedure (TCLP) and a cradle-to-gate life cycle assessment (LCA). At 100 % slag replacement, the work of cohesion increased by 28.7 %, moisture susceptibility declined by 45.9 %, and deformation and bleeding were reduced by over 40 %. The LCA indicated reductions in global warming potential (11.54 %), acidification potential (12 %), and cumulative energy demand (10.92 %), due to avoiding virgin filler production and lowering bitumen consumption. TCLP confirmed leached heavy metals below regulatory limits, supporting environmental safety and circular economy goals.
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