The aim of the paper is the development of a design catalog and sustainability analyses of road layers. In this paper, the material and thickness of the layers for three different traffic load classes will be determined based on the pavement design of the Hungarian and Pakistani standards. This was achieved using the Hungarian design method and the AASHTO method adopted by the National Highway Authority in Pakistan. "This will enable engineers in the field to choose pre-established designs from the catalog.". The forefront of pavement design is the direction in which ongoing research endeavors in the field are guiding us. The empirical design, as outlined in the AASHTO 1993 version, relies on statistical models derived from road tests. Moving beyond this, the mechanistic-empirical design involves assessing stresses and strains alongside empirical models, such as the MEPDG approach. Looking ahead, a mechanistic design encompasses models based on mechanics and represents the frontier where researchers are advancing the future of pavement design. The Hungarian pavement design method (eÚT 2-1.202:2005, 2005) primarily relies on mechanistic-empirical pavement design principles. However, it limits practicing engineers to choosing predefined designs from the catalog. The Comparison was carried out between Hungarian and Pakistani pavement designs. Subsequently, comparative calculations between GRT and SBS will be made for CO2 emissions and other sustainability parameters. To achieve this aim, the Pavement LCA tool by the US Department of Transportation Federal Highway Administration was employed.

This study's subject is the effectiveness of substituting Thar Coal Fly Ash (TCFA) for ordinary Portland cement, also known as OPC. Tharparkar, Pakistan, possesses the world’s third largest coal reserves, with deposited coal fuel of 175 billion tons and capable of providing energy for over 200 years. Thar Coal is a lignite type that produces 7-10% of by-products in ashes; among them, Fly Ash is a significant waste. Reusing this waste as a partial cement replacement offers an environmentally friendly solution. This study prepared concrete specimens with varying proportions of TCFA (0%, 10%, 20%, and 30% by mass) as cement substitutes. Compressive strength tests were conducted on 36 cubes (100mm x 100mm x 100mm) with different fly ash percentages at a proportion to water to cement of 0.52. Ages 7, 14, and 28 days for curing were considered. The findings demonstrate that a higher TCFA component enhances the workability of the concrete. At all curing ages, the strength in compression at a 20% TCFA replacement level was greater than that of standard concrete. However, as the cement replacement was increased to 30%, there was a slight decrease in the comparative compressive strength compared to regular concrete. The tensile strength of the splitting test, performed after twenty-eight days of curing age, reveals that it surpassed conventional concrete for all replacement levels. Considering the favorable outcomes in workability, constrictive strength, durability strength, and substantial economic and environmental benefits, there is much potential for using TCFA as a cement substitute in the construction sector.