Construction and Building Materials 494 (2025) 143552 Contents lists available at ScienceDirect Construction and Building Materials journal homepage: www.elsevier.com/locate/conbuildmat The influence of aggregate gradation on the macro-micro damage evolution characteristics of concrete after the action of abrasion Yang Li *, Haisheng Zha , Yanlong Li , Ruijun Wang , Kai Kong State Key Laboratory of Water Engineering Ecology and Environment in Arid Area, Xi’an University of Technology, Xi’an, Shaanxi 710048, China A R T I C L E I N F O A B S T R A C T Keywords: Aggregate gradation Abrasion resistance performance 3D scanning ITZ thickness Griffith’s microcrack theory Concrete structures in engineering applications are subject to erosion damage by high-speed sand-laden water flow, resulting in surface spalling, microcrack propagation, and mechanical property degradation, which severely threaten structural durability. However, systematic studies on the influence of aggregate gradation on the abrasion resistance of concrete under high-speed sand-laden water flow remain limited. In this study, granite and marble aggregate concretes were selected as research objects, and three aggregate gradations were designed. Through compressive strength tests, abrasion tests, 3D scanning, microhardness, and scanning electron micro­ scope (SEM) analysis, the influence mechanism of aggregate gradation on the macro- and micro-abrasion resistance of concrete was investigated. A theoretical relationship between Interface Transition Zone (ITZ) thickness and macroscopic performance parameters was established. The results indicate that the abrasion damage gradually extends from the surface erosion zone toward the central mortar erosion zone, and the aggregate content significantly influences the damage evolution. With the increase of fine aggregate proportion, the concrete’s mass loss and abrasion depth first decrease and then increase, while the compressive and abrasion resistance strengths first increase and then decrease. When the fine aggregate proportion is 40 %, the concrete exhibits optimal performance, with a cumulative 48 h abrasion strength loss of only 14.86–15.10 %, the ITZ thickness reaching a minimum of 4.90μm to 5.92μm, and the highest corresponding microhardness. The fitting model established based on Griffith’s microcrack theory further shows that ITZ thickness is significantly and linearly negatively correlated with macroscopic mechanical parameters, with an average fitting deviation of no more than 3.04 %, demonstrating high accuracy. 1. Introduction Large-scale hydroelectric power stations, water conveyance tunnels, and other hydraulic engineering projects provide security for the fundamental water resources on which human survival depends [1]. The safe operation of hydraulic structures is crucial for water storage and transportation, Hydraulic structures operate in extremely harsh envi­ ronments, leading to significantly shortened service lives [2,3]. Abra­ sion damage is the primary factor causing other issues, with approximately 70 % of dam spillway structures experiencing varying degrees of abrasion damage [4]. The abrasion resistance of concrete mainly depends on aggregate parameters, mix proportion, mechanical properties, cement type and dosage, fiber content, surface treatment, and porosity [5–7]. With the large-scale construction of high-head and high-discharge hydraulic projects, the abrasion problem of conventional concrete under complex hydraulic conditions has become increasingly promi­ nent. As the primary constituent of concrete, the gradation character­ istics of aggregates directly affect its compactness, ITZ properties, and overall abrasion resistance [8]. Optimizing aggregate gradation is therefore a key factor in ensuring the durability and operational safety of hydraulic structures [9]. Scholars have been devoted to the effects of aggregate properties on concrete performance [10–12]. The size effect induced by aggregate gradation is considered one of the key factors influencing the mechanical properties of concrete. Increasing the maximum aggregate size can enhance fracture energy under high loading rates and reduce the sensitivity of splitting tensile strength to size effects [13,14–16]. Aggregate shape and content significantly affect impact energy dissipation [17]. Moreover, aggregate types such as recycled aggregate [18], waste glass aggregate [19,20], and desert sand * Corresponding author. E-mail addresses: LY1990120311@163.com (Y. Li), 18691080790@163.com (H. Zha), liyanlong@xaut.edu.cn (Y. Li), wrj7163@xaut.edu.cn (R. Wang), kk15689757321@163.com (K. Kong). https://doi.org/10.1016/j.conbuildmat.2025.143552 Received 28 June 2025; Received in revised form 27 August 2025; Accepted 6 September 2025 Available online 9 September 2025 0950-0618/© 2025 Elsevier Ltd. All rights are reserved, including those for text and data mining, AI training, and similar technologies. Y. Li et al. Construction and Building Materials 494 (2025) 143552 [21], along with their pretreatment methods, can alter the phase composition, degree of carbonation, and porosity at the microscale, thereby influencing the mechanical and durability properties of con­ crete. Zheng et al. [22] demonstrated that aggregate content, maximum particle size, and gradation curve significantly affect concrete strength. Talat et al. [23] further compared the performance of ten aggregate gradations in porous mixtures, finding that porosity and abrasion loss were not strongly correlated. In addition, experimental studies confirmed that the coarse-to-fine aggregate ratio [24] and abrasion angle [25] are important parameters governing the abrasion resistance of concrete. Significant progress has also been made in experimental methods and theoretical modeling of concrete abrasion damage and ITZ thick­ ness. Tang et al. [26] employed molecular simulations to reveal the mechanical behavior, microstructure, and erosion resistance mecha­ nisms of recycled aggregate concrete ITZ. Yin et al. [27] clarified the strength variation mechanisms of ITZ at different spatial positions and established a strength prediction model based on ITZ pore structure characteristics, spatial heterogeneity, and water-to-cement ratio pa­ rameters. Advances in microscopic detection technologies have further facilitated the characterization of the internal structural evolution of concrete. Techniques such as microhardness testing [28], 3D scanning [29], digital image analysis [30], and X-ray computed tomography [31] have been widely applied to quantify ITZ properties, aggregate morphology, and internal damage. Under harsh service conditions such as freeze–thaw cycles [32], salt-frost environments [21], and long-term water flow erosion [33]. Su et al. [34] proposed corresponding char­ acterization methods and performance prediction models, and explored the influence of strength, aggregate parameters, flow velocity, and sediment concentration on the abrasion resistance of concrete. However, systematic studies on the regulation of macroscopic abrasion resistance and the microstructural ITZ evolution mechanisms influenced by aggregate gradation are still lacking. In this study, con­ crete prepared with granite and marble aggregates from real engineer­ ing projects was used as the research object, and three aggregate gradations were designed. Based on high-speed underwater steel ball abrasion tests and SEM, and supported by Griffith’s microcrack theory, the abrasion resistance, microhardness, and ITZ thickness of concrete were systematically analyzed. The quantitative influence mechanism of aggregate gradation on the macro–micro evolution process during abrasion was further explored. This study aims to provide a theoretical foundation for optimizing aggregate gradation of concrete under prac­ tical service conditions, and to offer scientific foundation for enhancing the durability and service life of hydraulic structures. 2. Materials and methods 2.1. Methodology This paper studies the abrasion resistance, microhardness and ITZ thickness of granite and marble concrete under different aggregate gradations. To better represent the overall steps, a schematic diagram was drawn, as shown in Fig. 1. 2.2. Materials The cement used was P.O 42.5 medium heat portland cement, the main chemical composition and properties of which are listed in Table 1. The selected class II fly ash’s main chemical composition and properties are presented in Table 2. Natural river sand with a fineness modulus of 2.75 was used as the fine aggregate, and its principal performance indices are given in Table 3. Two types of coarse aggregate granite and marble with particle size ranges of 5–10 mm, 10–20 mm, and 20–30 mm were employed, and the morphologies of these coarse aggregates are shown in Fig. 2. The admixtures comprised a DH9 air-entraining agent and a GK-3000 polycarboxylate high performance superplasticizer. The mixing water was ordinary tap water. 3D scanning test (every 12h) Abrasion resistance test Compressive resistance test SEM Aggregate 50mm ITZ 100m m Mortar Concrete slicing and coring treatment after abrasion Microhardness Fig. 1. Technology roadmap. 2 Test area (1mm interval) Y. Li et al. Construction and Building Materials 494 (2025) 143552 Table 1 Main chemical composition and properties of cement. Strength class Main chemical composition (%) Compressive strength(MPa) Setting time(min) CaO SiO2 P.O 42.5 58.53 24.73 Al2O3 3-d 28-d Initial set Final set 4.48 22.8 43.6 205 249 Density (g⋅cm− 3) Stability 3.16 Qualified Table 2 Main chemical composition and performance of fly ash. Main chemical composition (%) SiO2 56.6 Fe2O3 Al2O3 CaO 7.6 21.3 4.2 Density (g⋅cm− 3) Specific surface area(cm2/g) Water demand ratio(%) Fineness (%) Firing loss (%) 2.1 3400 102 18.0 3.6 50 %, respectively. On this basis, experiments were carried out to investigate the effects of aggregate gradation on concrete abrasion resistance, ITZ thickness, and microstructural properties. The coarse aggregate gradation curves adopted in this study are shown in Fig. 3. Table 3 Technical performance indices of fine aggregates. Fineness modulus Apparent density (kg⋅m− 3) 2.75 2540 Packing density (kg⋅m− 3) Loose Tightness 1480 1785 Silt content (%) 2.4. Test methods 1.3 2.4.1. Compressive strength test To evaluate the relationship between the abrasion resistance and mechanical strength of hydraulic concrete, the compressive strength was tested in accordance with the Chinese standard DL/T 5150–2017 "Technical specification for testing hydraulic concrete" [38]. Before abrasion, cubic specimens of 100 mm× 100 mm× 100 mm were pre­ pared. Core sampling was carried out using a drilling machine to obtain cylindrical specimens with dimensions of Φ 50 mm×h100mm. The Fig. 2. Aggregate morphology. 2.3. Experimental proportion The gradation of aggregate particle size directly affects the density and abrasion resistance of concrete. This study uses the improved gradation model based on Dinger-Funk proposed by Cao [35] and Li [36] for aggregate configuration. Typically, the maximum particle size should not exceed 1/4–1/3 of the thickness of the concrete specimen. A stepwise binary mixing method is employed, starting with small-volume aggregate with a particle size of 5–10 mm as a variable to maximize the concrete’s packing density [37]. As shown in Table 4, three continuous gradation schemes were designed, with mass ratios of 5–10 mm, 10–20 mm, and 20–30 mm aggregates set to 30:40:30, 40:30:30, and 50:30:20, corresponding to small aggregate dosages of 30 %, 40 %, and Fig. 3. Coarse aggregate gradation. Table 4 The mix proportion of concrete with different coarse aggregate gradations. Group G1 G2 G3 M1 2 M3 Water-binder ratio 0.35 0.35 0.35 0.35 0.35 0.35 Sand ratio (%) Fly ash (%) Water reducing agent (%) 33 33 33 33 33 33 20 20 20 20 20 20 0.7 0.7 0.7 0.7 0.7 0.7 Air entraining agent (%) 1 m3concrete material quantity(kg/m3) Water Cement Fly ash Sand 0.02 0.02 0.02 0.02 0.02 0.02 120 120 120 120 120 120 274 274 274 274 274 274 69 69 69 69 69 69 610 610 610 610 610 610 3 Stone (mm) 5–10 10–20 20–30 371.4 495.2 619 371.4 495.2 619 495.2 371.4 371.4 495.2 371.4 371.4 371.4 371.4 247.6 371.4 371.4 247.6 Y. Li et al. Construction and Building Materials 494 (2025) 143552 compressive strength test of concrete was conducted using the WAW-1000 universal testing machine, and the loading rate was set at 0.4 MPa/s. indentation. 2.4.5. SEM The JSM-6700 F scanning electron microscope was used to assess the effect of aggregate gradation on the internal microstructure of concrete specimens after abrasion, and representative images were selected to measure the average thickness of the ITZ, with 25 micrographs acquired for each specimen group. First, aggregate and cement paste samples that met the test requirements were sectioned from the abrasion damaged regions of the specimens, and surface dust was removed using com­ pressed gas, the samples were then mounted onto specimen stubs with double-sided adhesive tape and connected with conductive gold paste to ensure sufficient electrical conductivity. Next, an ion sputter coater was used to deposit a thin gold layer on the samples to improve imaging quality. Finally, the prepared specimens were placed in the SEM observation chamber for analysis. 2.4.2. Abrasion resistance test According to the Chinese standard DL/T 5150–2017 "Technical specification for testing hydraulic concrete" [38], the high-speed un­ derwater steel-ball method was employed to evaluate concrete abrasion resistance. The abrasion specimens measured Φ300 mm × h100 mm, and the test apparatus is shown in Fig. 1. Before testing, the cured specimens were fully immersed in water for over 48 h, their surface moisture was wiped off, and the initial mass was recorded. During the test, steel balls were placed on the concrete surface to simulate erosive particles. A total of 70 balls were used, comprising 10 with a diameter of 25.4 ± 0.1 mm, 35 with a diameter of 19.1 ± 0.1 mm, and 25 with a diameter of 12.7 ± 0.1 mm. The balls were made of high-hardness grinding steel with a Rockwell hardness ≥ 60. The apparatus was operated at a rotational speed of 4000 r/min, with a near-bed flow ve­ locity of approximately 3.8 m/s [39]. The standard test duration was 720 min, with an intermittent operation period of 120 min. After each 720 min test cycle, the specimens were removed to measure the mass loss. These steps were repeated until the total abrasion time reached 2880 min. The mass loss rate and abrasion resistance strength of the specimens were calculated using Eq. (1) and Eq. (2), respectively. △M = m0 -m1 × 100 m0 3. Test results 3.1. Compressive strength Fig. 4 shows the compressive strength of concrete before and after abrasion. This figure clearly indicates that with the increase in the proportion of small-sized coarse aggregates, the compressive strength of concrete initially increases and then decreases. Before abrasion, the G2 specimen exhibited the highest compressive strength of 50.27 MPa. Compared with G2, the compressive strengths of the G1 and G3 speci­ mens decreased by 21.92 % and 13.31 %, respectively. The compressive strength variation trend of the M1 to M3 specimens is similar to that of the G1 to G3 specimens. Before abrasion, the M1 group specimens exhibited the lowest compressive strength of 38.96 MPa. With the in­ crease in the proportion of small-sized coarse aggregates, the compres­ sive strengths of the M2 and M3 specimens increased by 18.45 % and 2.39 %, respectively. After 48 h of abrasion, the G2 and M2 group specimens still maintained the highest compressive strengths, at 32.32 MPa and 24.33 MPa, respectively. Compared with the values before abrasion, their compressive strengths decreased by 35.71 % and 47.28 %, respectively, which represented the smallest reduction ratios. This strength variation is not only related to the content of smallsized aggregates but also closely associated with the aggregate skel­ eton structure formed by different gradations [22]. When the proportion of small-sized aggregates is too low, it is insufficient to fill the internal voids of the concrete, resulting in fewer contact points between (1) Where △M(%) is the mass loss rate, m0(kg) is the initial mass of the specimen, m1(kg) is the mass of the specimens after abrasion. fa = tA △m (2) Where fa(MPa) is the abrasion resistance strength, A(m2) is the abrasion area, t(h) is the abrasion time, △m(kg) is the mass loss of the specimen after t time. 2.4.3. 3D scanning test 3D scanning test is a detection method based on multiple line beam lasers to obtain 3D point cloud data on the surface of objects, which is mainly used to collect point cloud data on the surface morphology of concrete specimens after abrasion [40]. Before scanning, mark points with diameter of 6 mm and 3 mm were uniformly pasted on the concrete surface successively. A handheld 3D scanner was used to scan the sur­ face of the specimen through mark point mode, and then the laser face mode was switched to scan again, and grid analysis was carried out to output cloud point data and polygonal mesh model. 2.4.4. Microhardness test An HVS-1000 microhardness tester was used for the tests, and the results are expressed in Vickers Hardness (HV) [41]. Before testing, a cutting machine was used to extract specimens along the direction perpendicular to the abraded surface of the specimens, and measure­ ment points on the cut samples were marked at 1 mm intervals. After multiple stages of polishing, the samples were placed under the micro­ hardness tester, a load of 4.90 N was applied for a dwell time of 10 s. The indentations were observed through a 400 × microscope objective, with the schematic of the test shown in Fig. 1. This test primarily measured the microhardness of the aggregate, the ITZ, and the mortar regions of the samples, with the HV values calculated according to Eq. (3). HV = F 2Fsin2α = d2 S (3) Where HV(MPa) is the microhardness value, F(N) is the test load, S (mm2) is the indentation area, α(◦ ) is the angle between the indenter, take 136◦ , d(mm) is the arithmetic mean of the diagonal of the Fig. 4. Compressive strength of concrete before and after abrasion. 4 Y. Li et al. Construction and Building Materials 494 (2025) 143552 aggregates, reduced plastic viscosity of the mortar, and the formation of a suspension-dense structure dominated by cement paste. In this case, loads are more likely to be transferred through the paste and the ITZ, leading to stress concentration, the development of more microcracks, and lower strength. Conversely, when the proportion of small-sized aggregates is too high, the main skeleton effect of the aggregates is weakened, and the strength relies more on the mortar matrix [42]. The larger specific surface area produces a thicker ITZ, which ultimately reduces the load-bearing capacity of the concrete. When the proportion of small-sized aggregates is 40 %, a denser and more interlocked skel­ eton structure is formed, optimizing the load transfer path and allowing the coarse aggregate skeleton to bear more pressure, thereby exhibiting the highest compressive strength [43]. and characterized by localized depressions formed by the abrasion of edge aggregates. The aggregate exposure region bounded by a yellow dashed line and representing a transitional state in which the aggregate surface has undergone slight wear. The core mortar erosion region bounded by a blue dashed line, which features selective wear of the cement mortar while the coarse aggregate remains relatively intact and still fully coated, with no obvious aggregate exposure. The specimen initial state exhibited a well-leveled surface, with the cement mortar fully encapsulating the aggregate and no interfacial de­ fects. During the early stage of the abrasion (0–12 h), wear was domi­ nated by the mortar layer. In the mid-stage (12–36 h), it transitioned to a composite wear phase of the concrete matrix, characterized by an increased exposure ratio of coarse aggregate and the formation of abrasion pits at the edge region with a maximum depth of 30.54 mm. The density of pits in the exposed region decreased, with only localized aggregate exposure. The central region remained relatively intact, dominated by slightly protruding aggregates. In the final stage (36–48 h), degradation of the ITZ caused the abrasion damage to reach its peak, with a maximum wear depth at the edge region of up to 44.33 cm. These abrasion-damage features are closely related to the 3.2. Apparent damage morphology Fig. 5 shows the damage evolution behavior of the concrete apparent morphology during the abrasion process. Under sustained abrasion, the abrasion surface of the specimen is divided into three typical damage regions [44]. The surface pitting region bounded by a red dashed line Fig. 5. The evolution of the apparent morphology of the specimen. 5 Y. Li et al. Construction and Building Materials 494 (2025) 143552 dynamics of the underwater steel-ball method [45], whereby during the test, the impeller drives the steel balls at 4000 rpm to generate a cen­ trifugal field, resulting in a significantly higher concentration of steel balls at the specimen edges than at the center. This spatial distribution difference leads to an increase in the abrasion energy per unit area at the outer margin. After 48 h of abrasion, the surface pits on the specimen exhibited pronounced irregularity and the aggregate exposure area reached its maximum, indicating that the irregular geometry of the eroded surface accelerates subsequent abrasion damage. The possible reason for this phenomenon is that the aggregate gradation alters the stability of the internal structure and the energy dissipation characteristics of concrete during abrasion, thereby signifi­ cantly affecting its abrasion resistance [46]. This is manifested in the irregular destructive patterns of mass loss and surface morphology. When the proportion of small-sized aggregates is excessively high or low, the mechanical interlock between coarse aggregates is weakened. In the relatively weak ITZ and mortar regions on the concrete surface, the probability of aggregate failure increases, and the stress concentra­ tion at the edges of the exposed pits is intensified, further aggravating the mass loss of concrete [47]. In contrast, an appropriate increase in the proportion of fine aggregates can improve overall compactness and matrix continuity, thereby alleviating local stress concentration and reducing mass loss. decreased and then increased. At 0–24 h, the G2 specimen had the lowest mass loss rate at 4.89 %, while the M2 specimen had the lowest at 6.42 %. After 48 h of abrasion, the cumulative abrasion rates of G2 and M2 reached 10.59 % and 14.05 %, respectively, which were the lowest among their respective aggregate groups. The results demonstrated a clear positive correlation with time. This indicates a nonlinear rela­ tionship between aggregate gradation parameters and abrasion resis­ tance, that is either excessively high or low proportions of small-sized aggregate reduce the abrasion resistance of concrete. The fundamental reason for the differences in concrete mass loss caused by aggregate gradation lies in the effect of gradation variation on the weak mortar matrix and ITZ at the concrete surface [48]. When the proportion of small-sized aggregates is either too low or too high, a thicker ITZ is formed. The spalling of large-sized aggregates is one of the main causes of mass loss. Under the combined action of high-speed steel balls and water flow abrasion, the dense ITZ interfaces and mortar matrix are more prone to synergistic damage, leading to aggregate displacement or complete detachment. The stress concentration at the edges of the exposed pits is then intensified, resulting in further dete­ rioration of the concrete. When the proportion of small-sized aggregates is 40 %, the impact energy of the steel balls is more evenly dispersed, and the damage mainly manifests as gradual deterioration of the mortar layer with only a few exposed aggregates (Fig. 5), resulting in lower mass loss per unit area. 3.3. Abrasion resistance test 3.3.2. Abrasion resistance Fig. 7 shows the abrasion resistance strength of concrete under different abrasion times. After 24 h of abrasion, the abrasion resistance strength of the G2 specimens was 1.97 MPa, and that of the M2 speci­ mens was 1.51 MPa, both being the highest values among their respective groups. Compared with the values at 12 h of abrasion, the strength of the two groups decreased by 7.89 % and 7.14 %, respec­ tively. After 48 h of abrasion, the cumulative loss rates of abrasion resistance strength for G2 and M2, with a 40 % proportion of small-sized aggregates, were the lowest, at 14.86 % and 15.10 %, respectively. Compared with G2, the abrasion resistance strength of G1 and G3 decreased by 19.23 % and 15.92 %, respectively, after 48 h. Similarly, compared with M2, the abrasion resistance strength of M1 and M3 decreased by 11.29 % and 27.78 %, respectively. The abrasion resis­ tance strength of the specimens exhibited a trend of first increasing and then decreasing with the increasing proportion of small-sized aggre­ gates, which is consistent with the variation pattern of compressive 3.3.1. Mass loss Fig. 6 shows the mass loss and mass loss rate of concrete under different abrasion times. The mass of the specimens was measured at 12 h intervals to accurately capture the variation patterns of mass loss rate over time. As shown in Fig. 6a, the overall mass loss of granite aggregate concrete is lower than that of marble aggregate concrete. After 48 h of abrasion, the mass loss of the G2 group was 1.86 kg. Compared with the G2 group, the mass losses of the G1 and G3 groups increased by 23.12 % and 16.13 %, respectively. Before abrasion, the mass of the M2 was 17.44 kg, the cumulative mass loss after abrasion was 2.45 kg. The M3 specimen exhibited the highest cumulative mass loss, reaching 3.15 kg. Compared with the M2 group, the cumulative mass losses of the M1 and M3 specimens increased by 12.24 % and 28.57 %, respectively. As shown in Fig. 6b, when the proportion of small-sized aggregate increased from 30 % to 50 %, the mass loss rate of concrete first 20 M3 0 14 G3 G2 G1 Mass loss(kg) 1 2 3 G1 12 10 4 M3 G2 M2 6 4 0 M 1 48 Ab ras 36 ion G1 M3 8 2 48 h G3 G2 M2 G3 36 h M 1 Mass loss rate(%) M3 M2 M 1 M2 16 h 12 G3 M 1 G1 G2 24 h 18 (a) Mass loss tim 24 e (h ) 12 G1 G2 (b) Mass loss rate Fig. 6. Mass loss and mass loss rate of the specimens after abrasion. 6 G3 M1 M2 M3 Y. Li et al. Construction and Building Materials 494 (2025) 143552 the proportion of mortar in the concrete matrix, but the limited strength of the mortar cannot provide sufficient load-bearing capacity. Under sustained abrasion, both of these conditions accelerate the failure of the concrete surface and significantly reduce its abrasion resistance strength [49]. 3.3.3. Abrasion depth Fig. 8 and Fig. 9 shows the 3D topography cloud maps of the concrete after abrasion, with the color gradient revealing the spatial distribution characteristics of abrasion damage. The abrasion depth spectrum ranges from shallow to deep as follows, purple, blue, green, yellow, and red [50]. To quantitatively investigate the effect of aggregate gradation on concrete abrasion depth, the point-cloud data acquired after each 12 h abrasion interval were analyzed to compute the average abrasion depth, as shown in Fig. 10. Before abrasion, the abrasion depth of the speci­ mens approached 0 mm, indicating that in the absence of external forces, the concrete surface exhibited no pits and the uniformity and compactness of the internal structure remained intact. After 24 h of abrasion, the cloud maps exhibited significant changes in color gradients (Fig. 8). With the deep purple areas in the central regions of all specimen groups substantially reduced; multiple blue protrusions indicate that the mortar layer had been eroded, leading to exposure of coarse aggregates, and small green regions appeared at the edges. At this time, the G2 group exhibited the minimum average abrasion depth of 5.97 mm. Compared with G2, the average abrasion depths of G1 and G3 increased by 10.89 % and 4.69 %, respectively. The average abrasion depth of marble aggre­ gate concrete was slightly greater than that of granite aggregate con­ crete. The M2 exhibited an abrasion depth of 6.60 mm. Compared with Fig. 7. Abrasion resistance strength of concrete after different abrasion times. strength. This phenomenon may originate from the interfacial mecha­ nism of concrete, wherein the bond performance between coarse aggregate and cement paste is governed by the interfacial yield stress and the plastic viscosity of the paste. A 30 % incorporation of small-sized aggregates leads to a heterogeneous aggregate–mortar distribution that more readily induces a porous structure, forming weak zones with stress concentration. A 50 % incorporation of small-sized aggregates increases 0 -10 -20 -30 -40 -150 -100 -50 X 0 0 50 50 100 100 150 150 -50 -100 -150 -50 -100 -150 0 100 150 -100 -50 Y 50 X 100 150 0 -10 -20 -30 -40 -150 -100 Y -50 X 0 0 50 50 100 100 -100 -50 48h Grinding depth(mm) X 0 -10 -20 -30 -40 -150 -100 -50 X 0 0 50 50 100 100 150 150 -50 -100 -150 -50 -100 -150 0 0 50 100 150 Grinding depth(mm) 0 -10 -20 -30 -40 -150 150 -50 -100 -150 -50 -100 -150 0 50 100 150 -100 Y -50 X 50 100 0 -10 -20 -30 -40 -150 150 -100 Y -50 X 0 0 50 50 100 100 M2 0 -10 -20 -30 -40 -150 -100 Y 50 Y -50 X 100 Grinding depth(mm) 24h Grinding depth(mm) M1 150 0 Grinding depth(mm) 50 Grinding depth(mm) 48h Grinding depth(mm) X 0 0 -10 -20 -30 -40 -150 150 0 -10 -20 -30 -40 -150 -100 -50 X 0 0 50 50 100 100 150 150 -50 -100 -150 -50 -100 -150 0 0 50 100 150 0 -10 -20 -30 -40 -150 -100 -50 Y 50 X 100 150 0 -10 -20 -30 -40 -150 -100 Y Fig. 8. 3D surface morphology cloud map of the specimen after abrasion. 7 150 150 -50 -100 -150 -50 -100 -150 0 0 50 100 150 Y 50 100 150 Y M3 Grinding depth(mm) -50 0 -10 -20 -30 -40 -150 G3 Grinding depth(mm) -100 Grinding depth(mm) 0 -10 -20 -30 -40 -150 G2 Grinding depth(mm) 24h Grinding depth(mm) G1 -50 X 0 0 50 50 100 100 150 150 -50 -100 -150 -50 -100 -150 0 0 50 100 150 Y 50 Y 100 150 Y. Li et al. Construction and Building Materials 494 (2025) 143552 G1 G2 Grinding depth(mm) 150 150 100 100 0 -16.50 -16.50 -16.50 -50 -50 -20.63 -20.63 -20.63 -100 -100 -24.75 -24.75 -24.75 -28.88 -28.88 -28.88 -150 -150 150 -150 -150 -24.75 Y -150 Y -100 Y -100 Y -20.63 -28.88 -150 -100 -50 150 100 100 50 50 0 0 X 50 100 M2 Grinding depth(mm) 150 0 0.000 150150 -100 -100 -150 -150 100100 -11.25 -100 -50 0 X 50 100 150 -50 0 X 0.000 0 50 X 50 100 100 150 150 M3 Grinding depth(mm) Grinding depth(mm) 0.000 0.000 -5.625 -5.625 -5.625 -11.25 -11.25 -11.25 -16.88 -16.88 -16.88 -16.88 -22.50 0 0 -22.50 -22.50 -22.50 -50 -50 -28.13 -28.13 -28.13 -33.75 -33.75 -33.75 -39.38 -39.38 -39.38 -28.13 -33.75 -100-100 -39.38 -150 -100 -50 50 50 Y Y Y -50 -150 -100 Grinding depth(mm) -5.625 -50 -33.00 -33.00 -33.00 -33.00 X -12.38 -12.38 0 -50 M1 -12.38 50 -50 150 -8.250 -8.250 50 -16.50 100 -8.250 -12.38 -8.250 0 50 -4.125 -4.125 100 0 0 -4.125 100 50 -50 0.000 0.000 150 50 -100 Grinding depth(mm) Grinding depth(mm) 0.000 150 -4.125 -150 G3 Grinding depth(mm) 0.000 -150-150 -45.00 -150 -45.00 -45.00 -45.00 -100 -50 0 50 100 150 -150-150 -100-100 -50 -50 0 0 X 50 50 100100 150150 Fig. 9. Cloud map of the abraded surface of the specimen after 48 h of abrasion. and yellow areas, with very few red areas and smooth color transitions. After 48 h of abrasion, the average abrasion depths of G2 and M2 were 12.26 mm and 13.98 mm, respectively, both of which are the smallest within their groups. A 40 % proportion of small-sized aggregates pro­ vides a denser concrete skeleton structure that effectively disperses the abrasion energy imparted by the steel balls and delays the progression of abrasion induced damage. Specimens with 30 % and 50 % small-sized aggregate content exhibited higher initial pit densities, which could not alleviate stress concentration during abrasion and became the dominant factor in later-stage abrasion damage. Significantly acceler­ ating the deterioration of the concrete structure and resulting in increased average abrasion depths. This also validates the influence pattern of aggregate gradation on the compressive strength and abrasion resistance strength of the specimens. 3.4. Microscopic test 3.4.1. ITZ thickness After the specimens were ground for 48 h, the microscopic mor­ phologies of coarse aggregates, ITZ and mortar were observed by SEM at magnifications ranging from 400 to 2500 times. The obtained image is binarized to form a darker contrast. ITZ and the matrix are distinguished according to the microstructure characteristics and contrast differences. ITZ is manifested as a darker ring-shaped area around the coarse aggregate. The ITZ thickness of each group of specimens was measured using image software (Fig. 11). The width of ITZ microcracks may be affected by the cutting method, resulting in uneven ITZ microcracks. Therefore, the reliability of the test results was verified by statistical methods, and the average width (WC), standard deviation (δ), coefficient of variation (CV), and extreme values (WC, max and WC, min) of the microcracks were shown in Table 5. Fig. 10. Average abrasion depth of the specimen after abrasion. M2, the abrasion depths of M1 and M3 increased by 1.97 % and 4.39 %, respectively. After 48 h of abrasion, the growth rate of abrasion depth increased to 0.26–0.43 mm/h. The abrasion damage extended from the peripheral weak zones further toward the central regions, with most of the blue areas transitioning to green and the red areas at the edges expanding, indicating an increase in damage depth. It is worth noting that in Fig. 9, the G2 and M2 specimens exhibit relatively high proportions of green 8 Y. Li et al. Construction and Building Materials 494 (2025) 143552 Fig. 11. SEM image of the specimen. 9 Y. Li et al. Construction and Building Materials 494 (2025) 143552 Fig. 11. (continued). 10 Y. Li et al. Construction and Building Materials 494 (2025) 143552 aggregate concrete. As shown in Fig. 12d-f, at the 1 mm measurement point, the M2 group exhibited an average ITZ microhardness of 77.4 MPa, and relative to M2, the microhardness values of the M1 and M3 groups at 1 mm decreased by 9.95 % and 19.38 %, respectively. At the 14 mm measurement point, the ITZ microhardness values of all groups approached 97 MPa, with M2 still presenting the highest microhardness, representing an increase of 26.36 % compared to the 1 mm region. The internal damage depths for the M1, M2, and M3 groups were 8–9 mm, 7–8 mm, and 9–10 mm, respectively. This phe­ nomenon can be explained by the microbleeding effect during specimen formation, which creates a distribution gradient within the internal aggregate-cement paste system. When the proportion of small-sized aggregates is 30 % and 50 %, the workability of the cement paste is adversely affected. The adsorption of moisture on the aggregate surfaces creates distinct water-rich layers, leading to pronounced heterogeneity in the internal concrete structure. The variation in ITZ thickness leads to differentiated microhardness in concrete under abrasion [53]. Table 5 Statistical parameters of ITZ thickness. Specimen WC(μm) δ(μm) CV(%) WC,max(μm) WC,min(μm) G1 G2 G3 M1 M2 M3 7.19 4.9 6.69 6.67 5.92 7.79 0.15 0.03 0.06 0.06 0.03 0.11 7.89 5.21 5.93 6.77 6.18 6.04 13.02 6.32 8.33 8.47 7.59 13.69 3.75 2.33 3.29 2.70 1.51 3.74 After 48 h of abrasion, the average ITZ thicknesses of specimens G1G3 were 7.19 μm, 4.90 μm, and 6.69 μm, respectively. Small-sized ag­ gregates exhibit a greater specific surface area and more contact in­ terfaces than large-sized aggregates. Therefore, the bonding strength between the G2 aggregates and the mortar is relatively stronger, resulting in a smaller ITZ thickness. Compared with G2, the average ITZ thicknesses of G1 and G3 increased by 46.73 % and 36.53 %, respec­ tively. Due to differences in the hydrophilicity of aggregate surfaces, the ITZ of granite aggregate concrete is denser and thinner than that of marble aggregate concrete. The M2 group exhibited a maximum ITZ thickness of 7.59 μm and an average thickness of 5.92 μm after 48 h of abrasion, compared with M2, the average ITZ thicknesses of M1 and M3 increased by 12.67 % and 31.59 %, respectively. This observation is consistent with the findings of Wang et al. [51], which indicate that an increase in ITZ thickness leads to a reduction in the abrasion resistance of concrete. When the bonding strength between the aggregate and the cement paste is low, under the combined action of water flow and steel-ball abrasion, the degradation of the ITZ is accelerated. Resulting in increased aggregate spalling and crack propagation in the concrete, thereby exacerbating abrasion damage. When the proportion of small-sized aggregates is 40 %, the concrete exhibits a narrower ITZ thickness. 3.4.3. Abrasion damage gradient The parameter Ki is introduced to describe the variation trend of microhardness when the local area changes from i to i + 1 [54]. The parameter Ki is the slope of the relationship between microhardness and the distance of the measurement point when the local area changes from i to i + 1: Ki = HV i+1 − HV i di (4) Where HVi and HVi+1 is the microhardness values in local region i and region i + 1, di is the distance between local region i and region i + 1. In Eq. (4), a Ki value greater than 0 indicates that, as the local area changes from i to i + 1, the microhardness increases, while a Ki value less than 0 indicates that, as the local area changes from i to i + 1, the microhardness decreases. When Ki > 0, it signifies that concrete abra­ sion damage exhibits a spatial gradient distribution characteristic, with larger Ki values indicating more pronounced gradient features. Fig. 13 shows The damage gradient of concrete after abrasion. Specimens near the surface damage region exhibit more prominent spatial damage gradients. In concretes with the same aggregate type, within region 1 the G2 and M2 groups exhibit the lowest K1 values of 5.05 N⋅mm− 1 and 4.63 N⋅mm− 1, respectively, indicating the smallest spatial damage gradient and a stronger ability to maintain structural integrity under continuous abrasion. As shown in Fig. 13a, the Ki value of G2 in regions 2–7 gradually decreases from 3.98 N⋅mm− 1 to 2.30 N⋅mm− 1 and stabi­ lizes in regions 8–12, demonstrating that after 48 h of abrasion, G2 re­ tains good integrity and compactness. As shown in Fig. 13b, the Ki value of M2 in regions 2–10 gradually decreases from 4.00 N⋅mm− 1 to 0.80 N⋅mm− 1 and approaches 0 in regions 11–12, validating previous experimental findings. In addition, due to the higher microhardness and greater hydrophilicity of granite aggregate concrete, it exhibits superior abrasion resistance performance and smaller damage gradients. 3.4.2. Microhardness Fig. 12 shows the microhardness distribution of aggregates, ITZ, and mortar at varying depths after 48 h abrasion. Microhardness testing commenced from coarse aggregates 1 mm beneath the abraded surface, with statistically averaged hardness values calculated for each depth. The ITZ manifests as a microcrack-prone weak region characterized by sparse clinker particles, abundant microdefects, and oriented enrich­ ment of plate-like calcium hydroxide crystals. Its thickness was deter­ mined by identifying abrupt transition zones in the hardness profile [52]. As shown in Fig. 12a-c, as the measurement points gradually move away from the coarse aggregate, the microhardness in all regions of granite aggregate concrete exhibits a trend of initially increasing and then gradually stabilizing. The microhardness of the ITZ fluctuates regularly with measurement point depth, indicating that it is more susceptible to structural damage under abrasion. At the 1 mm mea­ surement point, the average microhardness of the ITZ in the G2 group is 84.4 MPa, compared with G2, the microhardness at 1 mm in the G1 and G3 groups decreases by 11.02 % and 3.55 %, respectively. At the 14 mm measurement point, the microhardness values of the ITZ for all groups are close to 106 MPa, with G2 still having the highest microhardness, which is 25.95 % higher than that at the 1 mm region. The microhard­ ness of the ITZ gradually increases within the range of 1–6 mm, while no significant differences are observed in the range of 7–14 mm, indicating that under abrasion, internal damage in the concrete has a certain threshold. When the microhardness of the ITZ stabilizes in a specific region, it can be considered that the specimen is undamaged. The in­ ternal damage depths for G1-G3 are 8–9 mm, 6–7 mm, and 8–9 mm, respectively. The distribution pattern of the ITZ microhardness in marble aggre­ gate concrete is similar to that in granite aggregate concrete, but the microhardness values are generally lower than those of granite 4. Discussions 4.1. The thickness of ITZ estimated by Griffith’s microcrack theory Griffith’s microcrack theory holds that there are many small cracks or defects in actual materials, and material failure begins with the largest crack [55]. Based on the ITZ thickness data measured by SEM, when the concrete is subjected to abrasion, the relatively weak ITZ first generates stress concentration under the action of external force, local cracks begin to expand, and gradually extend to the concrete matrix until they penetrate. Since the composition of the base concrete and the water-cement ratio remain unchanged, it can be considered that γ re­ mains constant. However, the change in the gradation of coarse aggre­ gates will cause changes in the ITZ thickness, ultimately leading to 11 Y. Li et al. Construction and Building Materials 494 (2025) 143552 Fig. 12. The microhardness of the specimens after 48 h of abrasion. 12 Construction and Building Materials 494 (2025) 143552 Y. Li et al. Fig. 13. Abrasion damage gradient of concrete after abrasion. alterations in the compressive strength and elastic modulus of the con­ crete. As shown in Eq. (5), the thickness of ITZ (C) is negatively corre­ lated with the compressive strength (σ ), and positively correlated with the elastic modulus (E) and the fracture surface energy (γ). C= 2Eγ are slightly larger than those for marble aggregate concrete. However, the overall error ranges of all groups remain relatively small. 4.2. The relationship between ITZ thickness and compressive strength (5) π(σ )2 The simple linear regression model between ITZ thickness and compressive strength is expressed as Eq. (6), where Y represents the compressive strength and X represents the ITZ thickness. As shown in the fitting results (Fig. 15), the trend of ITZ thickness is inversely pro­ portional to the trend of compressive strength, indicating a strong linear correlation for both. When granite is used as aggregate, the ITZ thickness increases from 5.00 μm to 7.00 μm, while the compressive strength decreases from 32.09 MPa to 22.54 MPa. When marble is used as aggregate, the ITZ thickness increases from 6 μm to 8 μm, and the compressive strength decreases from 23.44 MPa to 18.13 MPa. This trend is consistent with the actual measured values of compressive strength, where the increase in ITZ thickness weakens the bond between coarse aggregate and cement matrix, affects the structural integrity, and ultimately leads to a reduction in overall strength [56]. Therefore, optimizing the ITZ microstructure through aggregate gradation can effectively improve the compressive strength of concrete. where σ (MPa) is the compressive strength of concrete, E(GPa) is the elastic modulus, γ(J/m²) is the surface energy of the crack per unit area, C(μm) is the ITZ thickness. The measured values of ITZ thickness, compressive strength of specimens and elastic modulus were substituted into Eq. (5) to obtain the fracture surface energy of granite and marble aggregate concrete of different gradations respectively. The relevant parameters are shown in Table 6. The fracture surface energies of granite aggregate and marble aggregate concretes are 4.15 J/m² and 3.63 J/m², respectively. Based on the previously obtained relevant parameters and Eq. (5), the calculated ITZ thickness values for each group of specimens are shown in Table 7. It can be seen that as the proportion of small-sized aggregates increases from 30 % to 50 %, the ITZ thickness exhibits a trend of first decreasing and then increasing. At a 40 % incorporation of small-sized aggregates, both the ITZ thickness and the macroscopic performance of the concrete are optimal. Fig. 14 shows the linear fitting relationship between the calculated and measured ITZ thickness values. When the coarse aggre­ gate is granite, the average deviation between the measured and calculated ITZ thickness values is 3.04 %, with the largest deviation of 6.13 % occurring in G3 and the smallest deviation of 0.56 % in G1. When the coarse aggregate is marble, the average deviation between the measured and calculated ITZ thickness values is 1.18 %, with the maximum deviation of 2.40 % in M1 and the minimum deviation of 0.51 % in M2. The calculation deviations for granite aggregate concrete Y = AX + B 4.3. The relationship between ITZ thickness and elastic modulus Fig. 16 shows the relationship between ITZ thickness and elastic modulus of concrete. When the ITZ thickness is minimal, the elastic modulus of the concrete is maximal, and the elastic modulus decreases as the ITZ thickness increases. For granite aggregate concrete, as the ITZ thickness increases from 5.00 μm to 7.00 μm, the elastic modulus of the concrete decreases from 19.44 GPa to 13.08 GPa, representing a reduction rate of approximately 3.18 GPa/μm. For marble aggregate concrete, as the ITZ thickness increases from 6 μm to 8 μm, the elastic modulus decreases from 14.37 GPa to 11.14 GPa, with a reduction rate of approximately 1.62 GPa/μm. These calculated results are consistent with the findings reported in the literature [57]. A decrease in ITZ thickness implies an increased contact area between aggregate and cement matrix, thereby enhancing the bond strength at the aggregate and matrix interface. This improved bond strength more effectively Table 6 Basic parameters of concrete after 48 h of abrasion. Aggregate type Group Compressive strength (MPa) Elastic modulus (GPa) Average thickness of ITZ(μm) γ(J⋅m− 2) Granite Marble G1~G3 M1~M3 24.67 20.46 14.79 12.29 6.26 6.79 4.15 3.63 (6) 13 Y. Li et al. Construction and Building Materials 494 (2025) 143552 Table 7 Calculated ITZ thickness of concrete after 48 h of abrasion. Aggregate type Granite Marble Group G1 G2 G3 M1 M2 M3 γ(J⋅m− 2) 4.15 3.63 Compressive strength (MPa) 20.94 32.32 21.74 19.6 24.33 17.46 Elastic modulus (GPa) 11.85 19.84 12.69 11.34 15.21 10.33 Average thickness of ITZ (μm) Calculated value Measured value 7.15 5.02 7.10 6.83 5.95 7.84 7.19 4.9 6.69 6.67 5.92 7.79 transfers stress under sustained loading, reduces stress concentration, and consequently increases the overall elastic modulus of the concrete. 4.4. The relationship between ITZ thickness and abrasion resistance strength Fig. 17 shows the relationship between ITZ thickness and abrasion resistance strength of concrete. As shown in Fig. 17, there exists a sig­ nificant relationship between the ITZ thickness and the abrasion resis­ tance strength of concrete. The fitting results demonstrate that the abrasion resistance strength of concrete is maximal when ITZ thickness is minimal, and the abrasion resistance strength decreases with increasing ITZ thickness. For granite aggregate concrete, when the ITZ thickness increases from 5.00 μm to 7.00 μm, the abrasion resistance strength decreases by 13.33 %. For marble aggregate concrete, when the ITZ thickness increases from 6.00 μm to 8.00 μm, the abrasion resistance strength decreases by 19.12 %. These fitting results are consistent with the findings in the literature, At 40 % proportion of small-sized aggre­ gates, the abrasion-resistance strength of concrete is significantly enhanced and the ITZ thickness is reduced. An increase in ITZ thickness implies the potential inclusion of more pores and microcracks, which weakens the bond between the mortar and the aggregate. When abra­ sion loads act on the concrete surface, they can weaken the local loadbearing capacity of the concrete matrix, leading to an increase in microcrack number and their rapid propagation inward, thereby accel­ erating the abrasion damage of the concrete [58]. Fig. 14. Relation between calculated and measured ITZ thickness values. Fig. 15. Relation between ITZ thickness and compressive strength. 14 Y. Li et al. Construction and Building Materials 494 (2025) 143552 Fig. 16. Relation between ITZ thickness and elastic modulus. Fig. 17. Relation between ITZ thickness and abrasion resistance strength. 5. Conclusions (2) Under high-speed underwater abrasion, the abrasion damage of concrete exhibits a multi-stage evolution, expanding from the peripheral erosion zones toward the central mortar erosion zones. Concrete with 40 % small-sized aggregates demonstrated the most uniform damage distribution, the lowest cumulative mass loss, and the slowest rate of damage depth propagation, with a minimum expansion rate of 0.26 mm/h. (3) Variations in small-sized aggregate content significantly influ­ ence the ITZ by altering the compactness of the aggregate skeleton and interfacial properties. As the proportion of small-sized aggregates increased, ITZ thickness showed a trend of initially decreasing and then increasing, while microhardness exhibited the opposite trend of initially increasing and then decreasing. Concrete under abrasion exhibited distinct spatial damage gradients and an internal damage depth threshold. This study systematically analyzed the macro-micro performance evolution of granite and marble aggregate concrete under high-speed water flow abrasion by setting three coarse aggregate gradations, and further revealed the intrinsic relationship between ITZ thickness and concrete abrasion damage based on Griffith’s microcrack theory. The main conclusions are as follows: (1) The content of small-sized aggregates is a key factor affecting the compressive strength and abrasion resistance of concrete. A small-sized aggregate proportion of 40 % was found to be optimal, corresponding to concrete with the highest compressive strength and the best abrasion resistance. 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Haisheng Zha: Writing – original draft, Investigation, Formal analysis, Data curation. Yang Li: Writing – review & editing, Methodology, Funding acquisition, Conceptualization. Declaration of Competing Interest The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper. Acknowledgments This study was financially supported by the Joint Funds of the Na­ tional Natural Science Foundation of China (Program No. U23A20673), the National Natural Science Foundation of China (Program No. 52479134), the Local Service Special Program of Shaanxi Provincial Department of Education (Program No. 24JE018), the Key Research and Development Program of Shaanxi Province (Program No. 2025SFYBXM-538). Data availability Data will be made available on request. References [1] W. Tian, M.H. Yan, W.R. 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