The size effect is a phenomenon where the strength and the ductility of a material depend on the size of the structure. Investigating size effects and related crack formation in brittle materials requires advanced monitoring methods. The aim of this research is to experimentally investigate the impact of size effect with the acoustic emission (AE) technique. Brazilian splitting tests with AE monitoring were performed on cement-based mortar cylinders of three sizes. It was found that in addition to the size, the boundary condition affects the final strength. When adopting similar boundary conditions in samples with different sizes, the larger samples had the lowest tensile splitting strength. For the larger samples, initially, there were fewer AE activities. However, there was a surge of high-amplitude AE events near the peak load. This indicates that as size increases, there is a lack of micro-cracking before macro-crack propagation, and the material fails in a more brittle manner. The width of the fracture process zone was quantified with AE and increased with sample size. A further analysis of the AE amplitude distribution demonstrated a change in the distribution in the pre-peak phase for the larger samples and for the smaller samples in the post-peak phase, signifying the brittle to ductile failure transition that occurs as size decreases.

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