Modification of asphalt pavement materials by using recycled waste tires in form of crumb rubber (CRM) is getting significant importance for saving resources as well as protecting ecosystem. So, in this study the crumb rubber size and percentage content effect on the performance properties of binder and mixtures were evaluated. A detailed experimental program has been performed using design expert software considering the variables like rubber size and content and their responses which were viscosity, Indirect Tensile strength (ITS), Tensile strength ratio (TSR) durability and Resilient Modulus (Mr). The viscosity of control binder with the addition of crumb rubber at high temperatures showed good improvement. The performance properties viz., ITS, TSR and Mr showed similar behavior as the size and content of crumb rubber increased under different loading conditions. The statistical models prepared using the analysis tool were found significant and well fitted based on high R2 (>0.80), high adequate precision value (>4), insignificant lack of fit and low p-value. Analysis of variance (ANOVA) model theoretical results generated by the response surface methodology (RSM) analysis were further validated by the experiments with <5 % of error showing good agreement between theoretical and experimental results. Study results showed that modified binder with 10 % crumb rubber passing sieve No. 40 in mixtures showed good improvement of mechanical properties indicating the potential source of recycled waste material usage in the pavement construction. •Recycled waste tires for saving natural resources and protecting ecosystem.•The effect of crumb rubber content showed improvement in the binder performance.•A detailed experimental program using design expert software.•Crumb rubber inclusion in HMA indicated good mechanical performance.