The incorporation of recycled concrete aggregate (RCA) into asphalt concrete supports circular economy goals by reducing reliance on virgin materials and minimizing construction waste. However, RCA’s inherent limitations, such as high porosity, microcracking, and poor interfacial bonding, compromise the structural integrity and durability of asphalt mixtures. This study introduces sugarcane molasses (SCM), a naturally derived, carbohydrate-rich byproduct of sugarcane refining, as a novel and eco-friendly surface treatment for RCA aimed at enhancing its compatibility with asphalt binders. SCM was applied at 5-6% by weight of RCA replacing coarse aggregate at varying levels (0-100%) to assess its effect on asphalt mixture performance. A comprehensive laboratory testing program was conducted, including microstructural analysis, aggregate impact and crushing strength tests, and performance evaluation using Marshall properties, resilient modulus, wheel tracking, moisture susceptibility, and fatigue resistance. SCM treatment resulted in a significantly denser and smoother interfacial transition zone (ITZ), reduced porosity, and improved cohesion at the aggregate-binder interface. Treated mixtures exhibited notable enhancements across all performance metrics: Marshall stability increased to 14.2 kN at 100% RCA, resilient modulus loss remained under 7%, Tensile strength ratio (TSR) values consistently exceeded the 80% threshold, and fatigue resistance peaked at 50% RCA with the highest asphalt flexibility ratio (AFR) and ductility. The findings demonstrate that SCM effectively mitigates the mechanical and durability shortcomings of untreated RCA. Among all mixes, 50% SCM-treated RCA yielded the most balanced performance. Although SCM treatment was found to be slightly cost-ineffective, the cost-performance index highlights its positive potential, particularly for 50% SCM-treated RCA mixtures. However, these results are material-specific, and field validation is essential to confirm performance across different RCA sources and environmental conditions.
