The major objective of this study was to investigate the suitability of utilizing tire-derived aggregates (TDA) at varying contents for the design of rubberized-asphalt base / subsurface layers through the dry process, along with (i) understanding the cracking potential and mechanical stress-strain response of the different materials under cyclic and confining stresses through triaxial resilient modulus (MR), dynamic modulus |E*|, and static semi-circular bend test, and (ii) assessing bonding strength of TDA with binder-aggregate matrix through moisture susceptibility test. The scope encompassed preparation of ten base course mixtures: one unbound granular base (UGB), three cement treated base (CTB), two asphalt treated base (ATB), and four rubberized-asphalt treated base (RATB) and obtaining mechanical performance at varying temperature-frequency combinations totaling 2636 data points. Triaxial MR tests indicated that CTB mix displayed highest modulus followed by ATB and RATB mixes, which was then followed by the UGB mix mainly ascribed to cement / asphalt treatment of the unmodified control subsurface material. Further, a finite element modeling study helped optimize the confinement levels to obtain realistic |E*| of ATB and RATB mixes. |E*| test results depicted that RATB mixtures would be rut-resistant at higher temperatures as they performed similar to the ATB mixes as well as crack-resistant at low to intermediate temperatures with significantly lower |E*| than ATB mixes, attributed to slower rate of change of viscosity with changing temperature in conjunction with enduring viscoelastic property (1.5–3 times higher phase angle than ATB) ascribed to high asphalt binder content and resilient nature of the rubber particles. Albeit the fracture toughness of ATB was twice higher than RATB, the latter had higher fracture energies, mainly due to the resiliency rendered by the rubber inclusions in concert with the extra viscous effect provided by the rubber-asphalt binder conglomerate. Based on the performance-based ranking, RATB mixes performed better than control mixes, and thus were adjudged as the most suitable alternative subsurface / base course materials in a pavement system. It is envisioned that this research will advance the current understanding of utilizing TDA in asphalt base / subbase courses using the dry process, and further assist in judging the viability of using rubberized-asphalt as potential sustainable alternatives to conventional systems to develop futuristic resilient pavement infrastructures with a strong emphasis on recycling of end-of-life tires, conservation of materials, and circular economy.
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