Asphalt is the most recycled material in the USA at a re-use rate of 99%. However, by average only 10 – 20% reclaimed asphalt pavement (RAP) is used in a given mix design and large part of the RAP is degraded for use in lower value applications. The amount of RAP in asphalt mixtures can be significantly increased with the application of good RAP management practice, readily available modern production technologies and advanced knowledge of mix design. This paper summarises the state-of-the-art approaches for increasing the amount of RAP in asphalt mixtures above 40%. The production challenges and common pavement distresses of very high RAP content mixtures are identified and methods to optimise the mix design as well as production technology in order to allow manufacturing of such sustainable mixtures are described. The best practices for RAP management and economic benefits of high RAP use are also discussed.