1. Introduction
Building structures made of concrete composites effectively protect against rain, moisture, noise, cold, and temperature fluctuations. In addition, the construction of buildings and structures made of concrete composites, as well as the subsequent maintenance and renovation of concrete structures, catalyze the development of world economies, thus significantly contributing to their economic progress and the increase of gross domestic products. Therefore, from an economic and social point of view, the dynamics of the development of the concrete industry is still highly desirable [
1,
2,
3].
One of the most important issues in the field of concrete and reinforced concrete structures is the ability to select the components of the concrete mix, and then carry out the technological process of molding the composite structure in such a way that the concrete after the curing period in a solidified form is characterized by the lowest possible number of initial microcracks [
4,
5,
6].
Having regard to the mechanical properties of cementitious materials, it is important to observe structure defects due to the fact that as stress concentrators, they constitute the cause of crack development and bring about material damage [
7,
8,
9]. According to the literature data, the area of first microcrack initiation in ordinary concretes is the Interfacial Transition Zone (ITZ) between the largest grains of coarse aggregate and the paste [
10,
11]. The role of this concrete phase is significant enough that according to [
12,
13,
14], the mechanical parameters and the material fracture toughness is not only associated with the strength of components which form the concrete structure, but to a large extent with the parameters of all contact zones in the composite, as well as material defects occurring even before application of the load.
The width of microcracks (
Wc) in the ITZ area also has a decisive impact on the degradation processes of structures made of concrete [
15,
16]. All discontinuities occurring in the structure of the cement matrix and the contacts between the inclusions and the continuous phase of the composite increase its permeability, thus enabling the migration of harmful and aggressive substances deep into the material structure [
17,
18,
19]. The presence of such media and their adverse impact on individual components of concrete may result in:
Acceleration of destruction of the material from which the structure is made;
Shortening the life of the structure;
Reducing the level of structure operation reliability;
Making impossible to ensure an adequate level of structure safety;
The need for more frequent and costly repairs.
For these reasons, knowledge concerning the size of material microcracks is important from scientific, engineering, and economic points of view [
20,
21]. The phenomenon of cracking in concrete composites and reinforced concrete structures is described in detail in an overview study concerning this subject [
22]. This article presents a detailed study of causes of crack formation in the concrete structure, and the places of their occurrence. Standard and modern methods of detecting microcracks and cracks were characterized and methods of minimizing their occurrence were outlined. It has been pointed out, among other things, that one of the methods for the design of composite structures with damage constraints is modifying the composition of the concrete mix in such a way as to obtain the smallest possible initial defects of the mature composite structure [
23,
24,
25]. For this purpose, the components of the concrete mix (mainly the binders) should be selected in such a way as to achieve a synergistic effect of interaction between the individual components used [
26,
27]. As a result of this, it is possible to obtain a more homogenous structure of the concrete mix, resulting in a more compact structure of the hardened concrete composite [
28,
29].
Therefore, concretes containing binders with a modified composition have been used for many years. Such modifications consist of replacing part of ordinary Portland cement (OPC) with other mineral materials [
30,
31]. Substitutes for cement binder are most often additives, and in recent years also nanoadditives [
32,
33]. In the simplest solutions, i.e., concretes based on binary binders, OPC is replaced by only one additional component, e.g., fly ash (FA), silica fume (SF), or metakaolin (MK) [
34,
35,
36]. The benefits which have been observed from such solutions include limiting the width of the initial microcracks in concretes of this type, reduction of porosity of such materials, and improving their mechanical parameters [
37,
38,
39]. In most cases, however, such effects resulted from strengthening the cement matrix structure through the development of additional C-S-H and C-A-S-H phases [
40,
41,
42]. Previous studies have shown, among other things, that a particularly positive effect on the microstructure of the ITZ area between coarse aggregate and paste is the modification of the composition of the cement binder with single additives and nanoadditives, such as:
Ground granulated blast furnace slag [
46];
Benefits in reducing the microcracks in the ITZ area have been also obtained when replacing mineral aggregates with recycled aggregates [
59,
60,
61] or coral aggregates [
62], and using sand concretes [
63]. In addition, the work [
64] presents the results of tests evaluating the effect of curing time on the size of microcracks in the ITZ area in concretes with the addition of FA.
However, more advanced solutions in this field of material engineering rely on the substitution of cementitious binder with a combination of two or even three active Supplementary Cementitious Materials (SCMs) [
65]. Such modifications are referred to as concretes based on ternary or quaternary binders [
66,
67].
As previous studies have shown, this type of concrete, in comparison with ordinary concrete, is characterized by:
Excellent mechanical parameters, i.e., with the results exceeding the results obtained for unmodified concrete by several dozen percent;
Fracture toughness increased by several to several dozen percent;
A more stable crack propagation process;
A more homogenous structure of the cement matrix.
It should also be mentioned that material modification in the form of concretes based on multi-component binders also includes pro-ecological activities. It has been proven that by reducing the consumption of OPC and the possibility of using waste materials as a substitute for the binder, such solutions cause [
68,
69,
70,
71]:
Significant reduction of CO2 emission;
Reduction of electricity and heat energy;
The possibility of waste management.
Due to the fact that material modification of concrete by a combination of several SCMs simultaneously contributes to both the improvement of properties of the composites with cement matrix and the development of sustainable construction, this article presents the results of new experiments assessing the size of microcracks in the ITZ area of such materials. The manuscript contains analyses of:
Based on the results of the experiments conducted, it will be possible to obtain information about the possibility of effective modification of concrete composites in terms of obtaining modern, innovative, and ecological materials with increased durability and increased reliability.
4. Results and Discussion
Figure 5,
Figure 6,
Figure 7 and
Figure 8 show exemplary representative images of the microstructure of individual tested composites. In accordance with the assumptions described in the first section of the manuscript, the analyses focused on both the assessment of morphological changes in the cement matrix and the measurements of the size of microcracks in the ITZ area of each concrete. Therefore, each of the drawings shows two characteristic areas at two basic magnifications, i.e., 8000× and 16,000×. In addition, in the case of concretes of the QBC series, the places of contact between the coarse aggregate and the paste were imaged at additional, very large magnifications. In this case, the following magnifications of the ITZ area were applied, respectively: 30,000×, 60,000×, and even 240,000×. In addition, in order to better highlight the changes in the structure of the analyzed concretes, all significant details observed were also marked on the selected representative photos. These included:
Main phases occurring in the cement matrix,
Areas of microcracks in the ITZ area, with the indication of their exact dimensions in three places,
Areas of occurrence of FA grains in the paste structure,
Voids after separation of FA grains from the cement matrix.
Table 6 describes the characteristic details visible in the cement matrix of all composites. In this table, attempts were made to briefly list the three most characteristic features that were most often visible in individual series of composites. In addition, the observed average microcracks width (
Wc) with error bars in the ITZ area of all composites are given in
Figure 9.
Based on the observations of the matrices of individual composites presented in
Table 5, it was found that the reference concrete was characterized by the most heterogeneous structure. Most of the phases present in this material were still in the process of reacting. Microcracks in the cement matrix were also observed (
Figure 5a).
Substitution of part of the cement binder with active pozzolanic additives resulted in a more compact and homogenous structure of the cement matrix in each of the QBC series concretes. However, the addition of only SF and nS in the concrete of the QBC-1 series caused only a slight change in the morphology of the matrix. In its structure, porous places were still visible, with agglomerates of concrete phases occurring therein during the reaction (
Figure 6a). Nevertheless, the surface of the fracture in this concrete was already clearly more compact than in the REF concrete.
In the concrete of the QBC-2 series, which contained both silica and FA additives in 5% quantities, the structure of the matrix was clearly compact, while FA grains visible in the paste were well integrated with the paste. Their contact with the surface of the matrix was compact, with almost imperceptible microdamages at the level of 20 nm (
Figure 7a). In this composite, it was possible to clearly observe the synergy effect occurring between the three SCMs used.
Increasing the amount of FA in the binder composition resulted in the effect of weakening the quality of the matrix structure. In this composite, i.e., QBC-3 series, unreacted FA grains had weak bonds with the paste surface. The places after their separation were also partly visible (
Figure 8a). The structure of the cement matrix was also less compact than in the case of concrete with a lower FA content, i.e., QBC-2 (
Figure 7a).
Therefore, the results of microstructural tests of concrete containing FA confirm the earlier results given, among others, in [
75]. On this basis, it can be concluded that the beneficial effect of FA additive in strengthening the structure of the cement matrix becomes evident in the case of using this useful waste only to a certain level. In the case of concretes modified by FA only, this is in the range not exceeding 20% [
76,
77,
78]. However, in the case of composites based on ternary or quaternary blended cements, the level of OPC substitution by FA should be much lower, preferably at the level of several percent [
79,
80].
After carrying out the microstructural assessment of individual composites, an analysis of the size of microcracks occurring in the ITZ area of the concrete in question was also performed. Based on the observations of the paste morphology in each of the materials, attempts were made to link these data with the results of Wc measurements.
When analyzing the average
Wc values, it should be stated that the modification of the basic structure of the cement matrix present in the REF concrete resulted in a significant reduction of the analyzed parameter in all concretes of the QBC series (
Figure 9). This is due to the fact that for the QBC-1, QBC-2, and QBC-3, the microcrack width of concrete composites was 0.70 μm, 0.59 μm, and 0.79 μm, respectively, indicating a decrease of 38%, almost 48%, and 30%, respectively, compared with the result obtained for concrete without additives.
Observed relationships are clearly visible when comparing the relative changes of
Wc in each of the concretes containing SCMs, compared to the result obtained for the reference concrete. This is shown in
Figure 10.
In addition, it should be stated that with a more advanced modification of the basic composition of the binder, the obtained
Wc results were less convergent, i.e., the size of the error bars in the average values of the analyzed parameter for QBC series concretes increased significantly. This was most clearly visible in concretes containing all three SCMs (
Figure 9). A larger dispersion of test results was also observed earlier in the study of mechanical parameters, and the parameters of the fracture mechanics of the same composites [
81,
82]. This phenomenon is probably caused by the heterogeneous reaction of FA grains or their partial separation from the matrix structure in the QBC-3 series concrete. This, in turn, has an impact on increased dispersions in the results obtained in concrete with these additives.
On the basis of the above results, it can therefore be concluded that the proposed modification of the binder composition in the analyzed materials clearly leads to:
The synergy between the additives and the nanoadditive used, which appeared during the formation of the cement matrix structure, made it more homogenous and less porous. In the case of QBC-2 and partly QBC-3 series concrete, it was completely homogenized. This, in the case of concrete modified with three active pozzolanic materials, led to the size of microcracks in the ITZ area of coarse aggregate with the paste being significantly reduced. The average values of
Wc decreased compared to the values obtained for the reference concrete (
Figure 10):
By almost 40% in the case of QBC-1 series concrete;
By almost half in the concrete of the QBC-2 series;
By 30% in concrete of the QBC-3 series.
Thanks to such favorable research results, it is possible to obtain composites that are less susceptible to damage and thus more durable, and do not require frequent repairs. This, in turn, reduces the global operating costs of buildings made of this type of material.