Achieving a balance between cracking and rutting resistance remains a key challenge in asphalt mixture design, particularly under varying materials and aging conditions. This study proposes a performance-based Balanced Mix Design (BMD) framework incorporating the IDEAL Cracking Test (IDEAL-CT) and IDEAL Rutting Test (IDEAL-RT). Eighteen dense-graded Hot Mix Asphalt (HMA) and two Stone Mastic Asphalt (SMA) mixtures were evaluated across multiple asphalt contents around the Optimum Asphalt Content. Results confirmed an inherent trade-off: increasing binder content significantly improved the Cracking Tolerance (CT) Index while decreasing the Rutting Tolerance (RT) Index. Notably, the RT Index exhibited a non-linear (U-shaped) relationship with binder content, reflecting the combined effects of air-void structure and film thickness. Using a 25th-percentile statistical approach to establish rational criteria, preliminary thresholds of CT Index ≥ 52 and RT Index ≥ 44 are recommended for dense-graded mixtures to balance durability and stability. SMA mixtures exhibited superior cracking resistance (CT Index ≥ 296); however, IDEAL-RT likely underestimated their rutting resistance due to its unconfined loading setup. Mid-term aging reduced cracking resistance through binder oxidation, yielding CT retention factors of 0.48 for dense-graded and 0.65 for SMA mixtures, highlighting SMA’s lower aging susceptibility. Finally, a field case study on plant-produced mixtures validated these thresholds for performance-based Quality Control/Quality Assurance (QC/QA). Overall, this framework links laboratory performance, statistical thresholds, aging, and field application, effectively enhancing conventional volumetric criteria.
