This research examines the environmental impacts and economic viability of roller compacted geopolymer concrete (RCGC) incorporating reclaimed asphalt pavement (RAP) as a sustainable alternative to conventional roller compacted concrete (RCC). A comprehensive cradle-to-grave life cycle assessment (LCA) and life cycle cost analysis (LCCA) were conducted for RCGC mixtures containing 0%, 20%, 40%, and 60% RAP by volume replacement of natural aggregates. The functional unit was one cubic meter of pavement material with a 40-year service life based on AASHTO design guidelines for major highway pavements (AASHTO 2008). RCGC mixtures with 40% RAP demonstrated 37% reduction in global warming potential with a standard deviation of 3% and 28% decrease in energy consumption with a standard deviation of 2% compared to conventional RCC. Life cycle costs were reduced by 14% with a standard deviation of 2% for RCGC-40 mixtures, overcoming higher initial material costs through enhanced durability and reduced maintenance requirements. Sensitivity analysis revealed that transportation distance variations of ± 50% resulted in 8–12% changes in environmental impacts, while alkali activator dosage optimization could reduce global warming potential by up to 14%. RAP processing energy variations of ± 30% affected total environmental impacts by less than 3%. Multi-criteria decision analysis identified RCGC-40 as the optimal mixture, balancing environmental benefits with economic viability and technical performance. The study demonstrates that RCGC with RAP provides a viable pathway for sustainable pavement construction in regions with abundant RAP resources and carbon reduction priorities.
