Studies on the Valorization of Aluminum Production Residues into Bituminous Materials at Different Scales: A Review

To conserve natural resources and reduce waste generation, the effective valorization of industrial waste and byproducts in engineering applications is becoming increasingly important. Among these materials, aluminum production residues (APRs) offer a promising and sustainable solution for road pavement applications. Unlike previous reviews, this paper uniquely examines recent research on the use of various APRs in bituminous materials across multiple scales, with particular attention to their roles as additives and fillers. The APRs examined included red mud (RM), aluminum dross (AD), and spent pot lining (SPL) residues, as well as secondary aluminum waste (SAW). These materials have been employed as additives in asphalt binders (microscale), as fillers in asphalt mastics (mesoscale), and as additives or fillers in asphalt mixtures (macroscale). Overall, this review indicates that adopting appropriate treatment approaches for APRs as asphalt modifiers can enhance their dispersion, thermal stability, rheological behavior, and leaching performance. In particular, the use of RM has been shown to improve thermal stability, tensile strength, intermediate-temperature cracking resistance, and rutting resistance, largely due to the increased stiffness it imparts to asphalt mastic and mixture phases. However, there is no clear consensus among researchers regarding other properties, as performance outcomes depend strongly on multiple factors, particularly the physicochemical characteristics of the RM, filler–binder ratios, testing methods, and reference filler types. Other APRs—such as AD, SPL, and SAW—have also shown beneficial effects on the performance of asphalt mixtures. There is still limited research on the influence of APRs physicochemical variability on asphalt–filler interactions and the performance of bituminous materials. For the safe and large-scale adoption of APRs, it is essential to establish standardized characterization procedures, testing methods, and application guidelines while considering diverse climatic conditions. Comprehensive assessments of cost and environmental impacts should also be incorporated to support informed decision-making by engineers and industrial stakeholders.