Synergistic Gypsum–Carbonation Strategy and Non-Contact ITZ Quantification for CFBFA Artificial Aggregate Concrete

This study explores an integrated strategy combining gypsum activation and pressurized flue gas heat curing (FHC) to enhance the interfacial transition zone (ITZ) in concrete incorporating over 80% circulating fluidized bed fly ash (CFBFA)-based artificial coarse aggregates. The inherently weak ITZ, characterized by low bonding strength and high porosity, remains a major limitation to the mechanical performance of CFBFA-based concrete. Gypsum promotes the formation of ettringite (AFt) and facilitates the development of a dense CaCO₃ shell through enhanced carbonation. Their synergistic effect improves microstructural homogeneity and reduces crack connectivity at the interface. A novel grayscale image-based double-peak gradient method is developed for non-contact, quantitative measurement of ITZ thickness, revealing a strong inverse correlation (R² = 0.87) between ITZ thickness and compressive strength. Microstructural analyses confirm that the dual treatment significantly refines the ITZ, resulting in denser aggregate interiors, improved matrix continuity, and more structurally integrated interfaces. The failure mode correspondingly shifts from interface-dominated fracture to composite-controlled behavior. These findings demonstrate the effectiveness of the FHC–gypsum approach in tailoring ITZ morphology and enhancing mechanical integrity, offering a viable pathway for high-performance, low-carbon cementitious composites utilizing industrial by-products.