Thin asphalt concrete overlays are a maintenance technique that mainly restore the functional properties of pavements. One of the main issues in thin overlays is reflective cracking that can cause early deterioration and reduce their service life. For this reason, the purpose of this investigation is to evaluate the effect of material selection on cracking performance of asphalt concrete mixtures for thin overlays. In particular, this paper evaluates the role of aggregate skeleton gradation. The study of the effect of aggregate gradation was divided into two stages: (1) fine fraction content and (2) maximum nominal aggregate size. Based on this, up to seven asphalt mixture gradations were designed and evaluated through the Fénix test at different test temperatures. The results showed a significant correlation between the fine fraction content, and maximum nominal aggregate size, and the cracking performance of the asphalt concrete mixtures. Mixtures manufactured with a low content of fine aggregates, as well as small nominal maximum size, experienced a further improvement of their toughness. These results reflected the importance of considering not only the effect of asphalt binder and environmental conditions but also aggregate gradation in the design of asphalt concrete mixtures in order to achieve a desirable cracking performance.

Traditional design procedures of asphalt mixtures are based on volumetric parameters and the compliance with the mechanical performance, while functional properties receive less attention. Additionally, even though the potential of sustainable technologies is proven, this is not sufficiently reflected in the technical specifications and their use is not widely spread. In order to face these challenges, the development of a useful tool that allows infrastructure managers an easy evaluation of the mechanical, functional, and environmental performance and the pursuit of balance between properties will encourage the optimization of road surfaces. The aim of this research is to develop a multi-labeling scheme for asphalt mixtures for thin wearing courses according to their mechanical, functional, and environmental attributes. In particular, the study focuses on the Spanish case, because all the collected data belong to the Spanish road network; however, the approached methodology is flexible enough to be adjusted to the requirements of individual countries. The findings in this research show promise because the developed labeling scheme allows not only the assignation of performance labels to any asphalt mixture based on its properties, but also the comparison of features between different asphalt mixtures.