To facilitate the high-value utilization of reclaimed asphalt pavement (RAP), this study investigated the efficacy of fine separation technology as a pre-treatment method. This technology significantly reduced the variability of RAP, controlling the coefficients of variation for asphalt content and aggregate gradation within 5% and 10%, respectively, and minimized false particle content (agglomerates of fines and aged asphalt). Response Surface Methodology (RSM) was employed to optimize the mix design for ultra-high-RAP- content mixtures (50–70%). A predictive regression model was developed to determine the Optimal Binder Content (OBC) based on RAP and rejuvenator dosage. The road performance of the resulting mixtures was comprehensively evaluated. Results showed that the technology markedly enhanced the overall performance of recycled asphalt mixtures. While high-temperature rutting resistance improved with increasing RAP content, low-temperature performance declined. The mixture with 70% RAP failed to meet low-temperature cracking requirements. Consequently, an optimal RAP content of 60% is recommended. Furthermore, the generalized sigmoidal model effectively constructed dynamic modulus master curves, accurately predicting the viscoelastic behavior of these ultra-high-RAP mixtures. This study demonstrates that fine separation is a critical pre-processing step for reliably producing high-quality, sustainable asphalt mixtures with RAP content far exceeding conventional limits.

High reclaimed asphalt pavement (RAP) contents are often limited by insufficient restoration of field-aged SBS-modified asphalt and the lack of a comprehensive method for rejuvenator dosage selection. This study aimed to develop a multi-performance-based approach for determining the dosage of an epoxy-based reactive rejuvenator under high-RAP conditions. Rejuvenated binders with different dosages were evaluated using conventional tests, DSR, MSCR, BBR, and LAS tests. Continuous low-temperature grading temperature, dissipated energy ratio, and entropy-weight TOPSIS were used for comprehensive evaluation, while GPC was employed to characterize molecular-weight distribution. The rejuvenator improved low-temperature relaxation, fatigue resistance, energy dissipation, and workability, whereas excessive dosages reduced rutting resistance and elastic recovery. Entropy-weight TOPSIS ranked RA-6 highest, with a relative closeness coefficient of 0.66504, and this ranking was consistent with the overall trends obtained from individual performance tests, supporting the feasibility of the proposed evaluation method. GPC results showed systematic changes in molecular-weight distribution after rejuvenation. For the investigated material system, 6% is recommended among the tested dosages. The proposed framework provides a practical basis for dosage determination when material characteristics and performance requirements vary.