<p>Road construction heavily depends on virgin building materials, which raises significant sustainability challenges due to resource depletion and environmental impact. With global infrastructure needs on the rise, the demand for road construction materials is projected to grow by 25–30% by 2040. This trend underscores the urgent need for alternative, eco-friendly solutions. One promising approach is the hot recycling of asphalt pavements, which utilizes Reclaimed Asphalt Pavement (RAP) to reduce reliance on new materials. This method offers potential benefits such as decreased energy consumption, lower greenhouse gas emissions, and reduced construction costs. This study presents a comparative analysis of existing hot recycling techniques specifically in-plant and on-site methods focusing on treatment efficiency, cost-effectiveness, and operational practicality. Key technical aspects such as aggregate gradation, binder aging, and rejuvenator performance are examined to assess their influence on recycled mix quality. Recent innovations in additives, modified binders, and mixing technologies are reviewed for their role in enhancing pavement durability and service life. Case studies across varied climatic zones and traffic conditions are analyzed to evaluate real world applicability. Environmental and economic assessments, including life cycle analysis (LCA) and cost–benefit comparisons, indicate that hot recycling can reduce carbon emissions by up to 30% and significantly cut material costs. Despite these advantages, challenges such as variability in RAP quality, complex mix designs, and limited long-term performance data persist. This review identifies key research gaps in binder rejuvenation, performance modelling, and regulatory frameworks. By critically comparing current practices and innovations, the study aims to support the broader and more efficient adoption of hot recycling in sustainable road infrastructure development.</p> Graphical abstract <p></p>