A general consensus exists in relating fracture behavior of cement-bas
ed materials to a fracture process zone that develops around and ahead
of the main crack tip. Nevertheless, there remains some disagreement
as to the nature and dimensions of the process zone. Some authors refe
r to the process zone as the main crack and its branches, while others
define it as a zone of microcracks around the main crack. Density and
distribution of increased microcracking around the crack have not yet
been directly observed and documented. Paper presents experimental ev
idence of the process zone occurring as a cloud of unconnected microcr
acks around and ahead of a Mode I macro-crack. Results show that, as t
he loading increases, a long and narrow process zone develops ahead of
the main crack tip. Its length is at least 15.2 cm (6 in.), and its w
idth is about 2 cm (0.8 in.) during the main crack movement. As the lo
ad further increases and the main crack starts moving, the process zon
e widens and reaches a width of up to 6 cm in its wake. The measured c
hanges in the characteristics of the process zone (i.e., its width and
micro-crack density) have been related to the change in specimen toug
hness. Influence of specimen geometry on the process zone dimensions a
nd specimen toughness has also been assessed. Microcrack data were col
lected through direct material observation by means of a scanning elec
tron microscope.