We engineered the next-generation bio-asphalt binder with enhanced performance by optimizing its production technology, paving the way for sustainable, high-performance roads. Comprehensive evaluations through rheological and tribological analyses, along with Life Cycle Assessment, confirmed its technical superiority. A standard pavement cross-section was meticulously designed following IRC guidelines, and a cost-benefit analysis was conducted. "The research findings were striking: our bio-asphalt demonstrated excellent storage stability, outstanding mechanical performance, and a marked reduction in both carbon footprints and construction costs, making it a smart, sustainable solution for the roads of tomorrow."