The foundry industry needs effective, alternative methods to reuse the recycled waste foundry sand (WFS) other than landfills, under the new lenient legislations in Finland. In this study, the viability of stabilized WFS and crushed rock mixtures were evaluated for applications in structural layers in pavements through a series of laboratory tests and analysis. Mechanical properties including flexural and compression strength of the binders, unconfined compressive strength and resilient modulus of the mixtures were determined by standard laboratory testing methods, to provide baselines for the viability evaluations. To ensure proper durability of the mixtures as pavement construction materials, the long-term performance was investigated in terms of frost heave and resistance to freezing-thawing cycles. In general, stabilized WFS and crushed rock mixtures showed great potentials in strength and durability for pavement structural layers. Cost and emission assessment also showed that the use of foundry sand in a filter layer is beneficial in reducing cost and CO2 emission by up to 50% and 46% compared with reference structures. This paper provides insight into the possibility and way of characterizing and improving recycled and secondary material properties for reuse in civil engineering projects. Recommendations are provided on how to further investigate and improve the properties of the stabilized WFS mixtures, and recycled materials in similar for reuse in pavement constructions.