Biochar has shown promising potential for soil remediation, yet its impact on heavy metals (HMs) immobilization often overlooks soil structure, which could influence soil cracking behavior and HMs transport. To address this gap, this study investigates the role of soil structure (dry density and aggregate size) on the cracking and cadmium (Cd) leaching behavior of biochar-amended fine-grained soils. A series of semi-dynamic leaching tests were conducted on samples with and without wetting-drying (W-D) cycles. Based on the proposed improved method for quantifying the effective diffusion coefficient (De) of Cd in unsaturated soils and microstructural analyses, we found that: (1) Higher dry density and larger aggregate generally resulted in smaller De by decreasing soil pore volume. (2) Biochar could connect isolated pores within large aggregates through its internal pores, yielding greater increases in De (294.8%–469.0%) compared to small aggregates (29.1%–77.4%) with 3% biochar. However, further increases in biochar dosage led to decreased De, primarily due to the dense pore structure. (3) Biochar effectively inhibited soil cracking, achieving the highest reduction of 36.8% in surface crack ratio. (4) After W-D cycles, samples exhibited higher De with increasing dry density, with aggravated cracking being the primary cause, suggesting preferential flow within the cracks, particularly those penetrating the soil. This study highlights the importance of careful consideration of soil structure and cracking potential before in situ field application of biochar as a remediation agent for HMs-contaminated fine-grained soils.
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