RFreund well that's a long and incomplete story! But the short answer is that I think the basic problem with installing the 24-inch piles is that they are using a rock bit. Fine for drilling into the Franciscan but not so good for drilling through soils. This really only came to light due to the monitoring report written by Ben Turner of Dan Brown & Associates, which I am guessing is why he was sent home! Some excerpts:
During drilling, air pressure varied from approximately 190 psi to 220 psi, water pressure varied from approximately 200 psi to 240 psi, and the water flow rate was approximately 20 gpm.
During each of these stops, the operator lifted the drill approximately 1 ft off the base of the excavation (i.e., by withdrawing the drill string up into the 24-in casing) and air continued to be circulated through the face of the tool and up the return line at approximately 200 psi. It is necessary to keep circulating air through the drill in order to continue flushing remaining spoils up and out of the return line; if the air pressure were to be abruptly stopped, the spoils would fall out of suspension and could cause clogging of the drill upon restarting. This is notable because of the potential for the drill to unintentionally “mine” soil during these intervals when air is circulating but downward drilling progress is not occurring. The greatest potential for unintentional mining would be in clean sand layers such as were encountered near the base of the Alameda Formation.
The pour log indicates that partway through pouring from the fourth grout truck, while the 24-in casing was being lifted such that the casing tip passed through the depth interval of approximately 260 ft to 256 ft below the top of guide wall, the grout level dropped from 19 ft to 37 ft below the top of guide wall. As grout pumping continued and the casing was withdrawn to the final tip depth of 243 ft, the grout level continued to drop to a low point of 67 ft below the top of guide wall before beginning to rise again. In total, the grout level dropped 48 ft over a period of about 30 minutes, corresponding to about 5 yd3 of grout loss plus the additional volume that was pumped during this time.
Note that the air and water pressures used to lift the cuttings are like 7 atmospheres! They did make a change to the device in the drill bit that cuts a slightly larger hole than the nominal diameter of the drill bit, but I doubt that made much difference. The biggest change was that Center Rock, the supplier of the drill bits and DBA were more carefully monitoring the pressures and so on. That didn't make much difference either.
During the actual installation of the piles there was a quite dramatic drop in the pore pressures in the Old Bay Clay. It is not very clear, at least to me, what this results from. Does the high-pressure reverse circulation have the effect of "sucking" water out of the clay, or is it just overmining creates a cavity into which water can flow? This drop in pore pressures and increase in effective stresses is then rather quickly reversed but some permanent settlement should result from that cycle of loading, in addition to settlement that results from overmining. For some unknown reason there has typically been a delay of several days before grouting, so that does not help. I believe that Jaxon van Derbeken is chasing down that story.