To meet the precast assembly and service performance demands of bridge deck asphalt pavements (BDAP), the balance design method and development procedures of self-leveling epoxy asphalt concrete (SLEA) were proposed based on guss asphalt concrete and epoxy asphalt concrete. The effects of different gradations and asphalt-aggregate ratios on the flowability and mechanical strength of SLEA were investigated. The rheological properties of SLEA during the mixing and paving periods were analyzed. Based on Bingham's plastic fluid mechanics properties, the generalized mixing viscosity of SLEA was defined. Considering aggregate morphological features including needle flake index, fractal dimension, as well as gradation composition characteristics including shape parameters and scale parameters, a prediction model for the rheological properties of SLEA during mixing and paving periods was built. Research results show that the flowability (at 200 ℃) of fine, medium, and coarse-graded SLEA10 is 15, 25, and 32 s, respectively, while the penetration (at 60 ℃) reaches 245, 233, and 228 (0.01 mm). All values exceed the specification requirements, demonstrating excellent flowability and mechanical strength to meet precast assembly and service performance demands. Gradation significantly influences SLEA10 flowability but has relatively small influences on its strength. The flowability mainly depends on the gradation fineness and aggregate characteristics, while the strength after molding mainly depends on the consolidation of epoxy asphalt, with gradation fineness playing a minor role. The established prediction model of generalized mixing viscosity achieves an determination coefficient of 0.94 between measured values and fitted values, demonstrating its effectiveness in predicting rheological properties. Based on the analysis results, it is recommended to choose the aggregates with regular size, low surface roughness, and finer gradation to realize the self-leveling and compaction-free function.
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