Performance Evaluation of an Eco-Friendly Prime Coat Material Formulated with Reclaimed Asphalt Pavement and Waste Bio-Oil

To address the insufficient interlayer bonding performance and high preparation costs associated with conventional prime coat materials for semi-rigid base asphalt pavement, in this study, we utilized waste bio-oil to enhance asphalt–aggregate separation in recycled asphalt pavement (RAP) and collected the filtrate after separation. The RAP–bio-oil filtrate acts as a diluent, which is reintroduced into the asphalt to form a novel prime coat material: RAP–bio-oil filtrate cut-back asphalt (RFCA). The optimal proportions of each component in RFCA were determined through penetration tests, interlayer shear tests, and interlayer tensile tests. Subsequently, interlayer shear strength tests were conducted to evaluate the bond strength of RFCA compared to traditional prime coat materials, such as PC-2 emulsified asphalt (PC-2 EA) and kerosene cutback asphalt (KCA). Additionally, interlayer shear fatigue tests were performed to assess the durability of the bond provided by RFCA between the surface and base layers. The experimental results indicate that the optimal formulation for RFCA comprises 60% asphalt by mass of the RAP–bio-oil filtrate and 10% penetrant agent by mass of the RAP–bio-oil filtrate. Under conditions of 15 °C, 40 °C, and 15 °C water immersion, the interlayer shear strength of RFCA demonstrates an enhancement compared to PC-2 EA and KCA. Compared to PC-2 EA, the interlayer shear fatigue life of RFCA improved by 39.7% at a stress ratio of 0.2, 40.8% at 0.3, 51.2% at 0.4, and 40.3% at 0.5. The application of RFCA as a prime coat material significantly enhances interlayer durability. Based on the cost analysis, the application cost per square meter for RFCA is lower than that of PC-2A. Consequently, RFCA presents a viable option as a green, renewable, low-cost, and high-performance prime coat material for application on semi-rigid base asphalt pavement.