BARRA GRANDE HYDROPOWER PLANT

DESIGN, CONSTRUCTION AND PERFORMANCE

Author: Jorge Magno Vieira Borges

Main Brazilian Dams III

BARRA GRANDE HYDROPOWER PLANT

DESIGN, CONSTRUCTION AND PERFORMANCE
1. INTRODUCTION
The Barra Grande powerplant is located in the Pelotas
River, at the border of the municipalities of Anita Garibaldi
(Santa Catarina State) and Pinhal da Serra (Rio Grande
do Sul State) as shown in Figure 1.
The concession for development of the powerplant
was granted to the consortium BAESA - Barra Grande
Energtica S.A., an association of VBC Energia S.A.,
ALCOA Alumnio S.A., CCCC Construes e Comrcio
Camargo Corra S.A. and DME Energtica
(Departamento de Municipal de Eletricidade de Poos
de Caldas).
Construction works at the site began in July 2001
and the project was implemented under a turnkey
contract by the UNEBAR Consortium, formed by CCCC
(civil works and erection), ALSTOM Brazil (main
equipment supplies) and ENGEVIX Engenharia S.A.
(engineering and substation supplies).
The first studies for development of the Uruguay basin
were undertaken by the Comit de Estudos Energticos
da Regio Sul - ENERSUL between 1966 and 1969 guided
by Canambra and reviewed in 1978 by Eletrosul. The
feasibilities studies were developed by Engevix.

height of 185 m.
The main features of the project layout are as follows:
A 185 m high and 650 m long concrete face rockfill
dam CFRD provides a total head of 167 m for power
generation.
The surface spillway equipped with six Tainter gates,
15 m wide and 20 m high, was designed for a peak
discharge of 21,800 m/s. The concrete chute is 274 m
long with two aeration steps, to prevent concrete
cavitation. A stilling basin will provide the dissipation of
hydraulic energy during high flows.
The power structures comprise a (51.30 m high and
30 m wide) concrete intake followed by three (450 m
long and 6.20 m diameter) concrete lined power tunnels.
The indoor powerhouse was designed to
accommodate three 236 MW Francis turbines.
The river diversion scheme comprises two unlined
tunnels, with arched-rectangular section (15 m wide and
17 m high) and lengths varying between 816 and 921 m.
The high peak floods on the Pelotas river led to the
construction of 61 m high cofferdam, designed for
1:50 year flood (discharges up 7,500 m/s). The first stage
of the dam (94 m) was designed for a 1:500 year event or
14,000 m/s of peak inflow.
A compensating tunnel (3.0 m diameter) controlled
by two valves will maintain an ecological discharge
downstream of the dam during reservoir filling.

The general layout of the Project is presented in

Figure 2.
The main structures for the project were tested on a
hydraulic model at the CEHPAR laboratory in Curitiba,
Brazil.

3. GEOLOGICAL AND GEOTECHNICAL

FEATURES
Figure 1 - Location map

2. LAYOUT
The normal maximum operating level of the reservoir
is at El. 647 m, with a drawdown of 30 m for flow regulation.
At the dam axis, the average elevation of the rock
foundation is at El. 466 m, resulting in a maximum dam
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The hydroelectric power plant is located in the South

portion of the Sedimentary Paran Basin. It comprises
sedimentary and volcanic rocks, dominated by basalts
of the Serra Geral Formation, in a mainly subhorizontal
distribution gently dipping to West. In the intervals
between flows, aeolian sand sediments from the
Botucatu Formation were deposited in restricted basins
(intertrappean sandstones).

Main Brazilian Dams III

Figure 2 - General Layout

In the upper part of the Serra Geral Formation, an

acid volcanic sequence occurs in some areas in the
Santa Catarina and Rio Grande do Sul States.The
nomenclature to define these acid volcanic rocks,
containing silica amounts greater than 66%, is still
debated, some of the suggested terms are vitrophyre,
granophyre or rhyodacite.
Usually, the majority of the basaltic flows are
characterized by dense basalts in the lower and central
parts of individual flows, with some vesicular at the base
and a vesicular-amygdaloidal zone in the upper part, with
a layer of basaltic breccia formed by basaltic fragments,
surrounded and welded by secondary minerals or by siltysandy materials at the top. Vesicular basalts at the base
and basaltic breccias at the top, may be absent in some
lava flows.
The local landscape reflects a pronounced
lithostructural control of the relief, making evident the
layered subhorizontal shape of lava flows. Along the
hillsides, the occurrence of steplike shapes of the slopes
is associated to flat areas, related to the upper zones of
the lava flows, intercalated by subvertical slopes related
to the central zones of the flows, where the rock has
predominantly a vertical columnar jointing zone. The bed
and the banks of the Pelotas River present a young erosion
pattern, with very steep and deep valleys with a narrow
"V" shape, averaging slope inclinations of 30 to 40,
without the development of typical alluvial flood plains.
At the dam axis, the valley is about 250 m high, the river

bed is 100 m wide and the water flow is about 1.0 m deep
in the dry season.
The exploratory drill holes detected a sequence of
fourteen basalt flows ranging approximately from El. 710
to 420 m, disposed subhorizontally, dipping about 0.5
downstream in the West direction. The soil overburden in
this area is shallow, less than 4 m deep and its contact
with the underlying rock is abrupt, without a transition
zone.
The rock mass, near the surface, is generally fractured,
with expressive water losses (more than 1l/min.m.atm),
associated with relief fractures. In its inner portion, the
majority of the contacts between individual lava flows are
sealed. There are large water losses in the river bed, more
than 10 l/min.m.atm, at the joint at El. 465 m and at the
contacts between the M/N lava flows (El. 450 to 455 m)
and at the N/O flow (El. 435 m). The most significant
water losses (higher than 10 l/min.m.atm) on the
abutments were detected in the F lava flow.
The main geotechnical factors of the dam foundation
are mainly related to the shallow zones, which are more
weathered and/or fractured, extending to inside of the
rock mass, which will demand careful dental treatments
to remove the material of poor geomechanical quality and
fill the cavities with concrete. On the left bank, between
the El. 615 and 625 m, the rock mass is much fractured
(more than 10 fractures/m). In the river bed, the dam is
located over rocks of the M flow, which present good
geomechanical conditions.
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Main Brazilian Dams III

4. HYDROLOGICAL AND HYDRAULIC

FEATURES
The Pelotas River (tributary of Uruguay River) at the
Barra Grande site drains a catchment area of about
13,000 km. The long-term average flow is 292 m/s and
floods can occur at any time of the year, but the largest
recorded ones always occur in the period from May to
October.
Barra Grande is a regularization river plant. Maximum
drawdown is 30 m for pondage. The volume of the reservoir
is about 2,286 hm.
The results of the flood frequency analysis are
illustrated in the following table:

The probable maximum flood (PMF) resulted

in 23,840 m/s.

5. DESCRIPTION OF THE MAIN

STRUCTURES
5.1. River Diversion
The diversion system comprised two cofferdams - one
upstream 66 m high and one downstream 25 m high and
two tunnels - 15.0 m wide and 17.0 high and with a length
from 816 m to 921 m The diversion design flood was
7,500 m/s, with an annual probability of occurrence of
1:50. The structures were closed by stoplogs, and
concrete plugs were built subsequently in the intermediate
part of the tunnels.
5.2. Dam
The dam has a crest 10 m wide and is located in a
very narrow valley. The ratio between crest length and
height is 3.65, with the abutments having an average
inclination close to 45. Total volume of embankment
originated from excavations in basalt rock was about of
12 million cubic meters, placed and compacted on sound
rock foundation.
The upstream and downstream slopes have
inclinations of 1V : 1.3H and 1V :1.2 H respectively. The
theoretical control slope of both upstream and
downstream faces is 1.3H : 1V. Transitions 2A and 2B
are compacted in layers of 0.50 m thickness, the
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embankments 3B and 3D of the upstream and central

zones were compacted in layers of 1.00 m thicknesses,
wetted in the ratio of 200 l/m during placement, and
embankments 3C and 3D of the downstream zone were
compacted in layers of 1.6 m without wetting.
The average void ratio of the upstream zones was
0.24 and average unit weight was 22.1 kN/m, the
unconfined compression tests showed that the strength
of the basalt rock was over 90 MPa. The downstream
third of the dam section showed an average unit weight
of 20.2 kN/m.
For protection of the processed transition and bedding
for the upstream slab, an extruded curb concrete was
poured with an average cement ratio of 50 kg/m.
The perimetral slab (plinth) and the concrete face slab
compose the watertight elements of the dam.
The face slab with a total area of about 108,000 m,
was built in 16 m wide strips, separated by longitudinal
joints.
All vertical joints are protected by copper joint seals
at the base of the slab. In the tensile region, near the
abutments, the joints are covered with a mastic-filled
PVC membrane.
The perimetral joint between the plinth and face slab
was protected by a copper waterstop and a surface
sealant (mastic) covered with a PVC membrane.
The thickness of the concrete face varied from
0.30 to about 1.00 m, according to the following formulas:
t = 0.30 + 0.0020 x H (for H up to 100 m)
(1)
t = 0.0050 x H (for H higher than 100 m)
(2)
Where:
t is the slab thickness; H is the water head in meters.
Double reinforcements were adopted in the first 20 m
of the slabs above the plinth, with a rate of 0.5% in both
directions. In this zone, the reinforcement was shared in
the two slabs surfaces, top and bottom, being 60 % on
the upper face and 40 % on the lower face. Reinforcement
of 0.3 % of concrete in the horizontal direction and
0.4 % in the vertical direction were provided in the central
zone of the concrete face.
The foundation treatment included consolidation and
curtain grouting under the plinth slab.
The rockfill followed the classical zoning for CFRD,
more careful grading and compaction were concentrated
in the upstream third of the dam.
Table I gives the physical indexes of rockfill materials
and Figure 3 shows a transversal section of the dam.
5.3. Spillway
The chute spillway, located on the left bank, has a
design capacity of 21,810 m/s and the outflow is controlled
by six radial gates measuring 15.0 m x 20.8 m.
For maintenance work there is a stoplog made up of six
interchangeable panels, operated by a gantry crane at
the crest of the spillway structure. A bridge at the crest,
made up of precast elements, links the intake structure
to the left bank.

Main Brazilian Dams III

Table 1 - Dam Materials

Figure 3 - Transversal section of the dam

The concrete lined chute is 274 m long and 111 m

wide and has an inclination of 22% with two aeration
steps. The reinforced slab of the chute is anchored to
the foundation rock by rock bolts with a diameter of
25 mm, spaced 2 m in each direction, in holes 3 m deep.
The flip bucket located the end of the chute, has a radius
of 30 m and an angle of 20, which directs the jet to a
dissipation basin 120 m wide. The longitudinal profile of
the spillway is shown in Figure 4.

5.4. Intake and Power Tunnels

The intake structure is a conventional concrete
structure founded in sound rock. It is 51.30 m high and
30 m wide.
The concrete lined power tunnels were reinforced to
control shrinkage cracks during construction.
Both, the vertical portion and the sloping portion have
two layers of longitudinal steel 16 mm each 20 cm, with
rings of 8 mm at 25 cm spacing, increased to
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Main Brazilian Dams III

Figure 4 - Longitudinal Profile of Spillway

16 mm each 20 cm where crossing weaker flow contact

zones in the vertical shafts.
The vertical upper curve has an empirically defined
double reinforcement of 16 mm each 20 cm both ways.
The lower vertical curve is similarly reinforced by
20 mm each 10 cm.
This reinforcing was planned to distribute cracks
eventually produced by radial and circumferential
deformation due to water pressure in order to reduce
leakages to a minimum.
Immediately upstream from the steel lined section,
the reinforcing was increased to double rings of 20 mm
each 20 cm internally and 8 mm each 25 cm externally
and longitudinal reinforcing of 16 mm each 20 cm
externally and 20 mm each 20 cm internally.
5.5. Powerhouse
The powerhouse is of the indoor type and is 92.0 m
long including the erection bay. The net head is 154 m
and the plant is equipped with three generation units,
each one rated 236 MW.
The control system of the power plant and substation
is of the digital type and in the event of an emergency it
can be controlled and supervised at the local level.

6. CONSTRUCTION
Construction facilities for Barra Grande included an
industrial yard containing basically: recreation centre,
water treatment plant, offices, warehouse, laboratories,
repair shop, substation, crushing and batching plants.

7. PERFORMANCE
7.1. Dam
The reservoir reached El 617.50 m on September 5th,
2005, sixty three days after diversion closure. Filling
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speed in this period was about 2,15 m/day, due to the

occurrence of heavy rains in the region.
On September 19th, 2005, the flow meter collecting
the water leakage through the dam recorded 220 l/s. Three
days later the leakage increased to 400 l/s. At this time,
when the filling of the reservoir reached El. 634 m, about
93% of its maximum head, concrete rupture (spalling)
was observed along the compression joint, between face
slabs 19 and 20, (see Photos 1 and 2).
An underwater investigation by divers and a robot
(used in offshore works) showed the spalling reached a
depth of about 100 m under water.
The reservoir was lowered to El 630.00 m and the
concrete slab and the joint above the water level were
repaired. Photos 3 and 4 present the repaired slab.
Filling of the reservoir restarted in November, 2005.
The maximum percolation through the dam recorded by
the flow meter located in the downstream cofferdam
reached a peak of 1,284 l/s.
In March the first placing of clay-silt material started
in order to seal the joint and the damaged concrete of
the slabs under water. This initial placing reduced the
infiltration flows to about 800 l/s. In July after the increase
in percolation, additional material was placed, totalling
about 22,000 m of clay-silt material. See figure 5.
The rupture, which occurred in the compression zone,
presented the characteristics of spalling caused by high
compressive stresses in the transversal and longitudinal
directions of the face slabs.
Settlements are being measured by Swedish box
settlement devices, placed across the dam at four levels,
and by magnetic settlement gauges placed in three vertical
sections.
Maximum displacement of the slab until the present
moment reached about 71 cm near the crest of the dam
and the specific deformations are varying between

Main Brazilian Dams III

Photo 1 - Concrete rupture between face slabs 19 and 20 before

cleaning of slab surface

Photo 3 - Repairing of the slab

Photo 4 - Repairing of the slab conclud

2 to 5 per cent. The general displacement and settlements

of the rockfill are shown in Figures 6 and 7, respectively.
The conclusions that can be reached based on the
results of the monitoring instrumentation and the
observation of the behaviour of the dam for the last
20 months (after filling the reservoir) are:
Photo 2 - Concrete rupture between face slabs 19 and 20 after
cleaning of slab surface

Specific deformations obtained are similar to other

CFRD dams constructed with basalt rockfill;

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Main Brazilian Dams III

Figure 5 - Percolation and Reservoir Level

Figure 6 - Deformation of the slab

Settlements observed during construction in the

Barra Grande rockfill are very similar to those measured
in similar dams such as Foz do Areia, Segredo, It and
others.
The leakage through the dam recorded on the
downstream flow meter at the present time is about
935 l/s, which could be considered acceptable considering
the dam dimensions and reservoir head and when
compared to other similar dams in operation around the
world.
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The analysis of the instrumentation data confirms

that the dam is completely safe, as it was for the first
filling, with leakage compatible with the size of the
structure and behaviour of the embankment within the
usual range observed in other concrete face rockfill dams.

Spillway
The instrumentation consisted of six standpipe
piezometers, installed from the drainage gallery in the
geological features of foundation rock and at the concrete
rock contact, six triorthogonal joint meters installed

Main Brazilian Dams III

Figure 7 - Settlements of rockfill

between blocks and three extensometers and a flow

meter to measure the seepage flow.
The results of the instruments indicated an adequate
behaviour of the structure. The maximum seepage
recorded was 101.95 l/min.
Intake
The instrumentation consisted of three standpipe
piezometers, they did not record any piezometric water
level in the foundation.
Powerhouse
The instrumentation consisted of ten standpipe
piezometers, installed from the drainage gallery in the
geological features of foundation rock and at the concrete
rock contact, nine triorthogonal joint meters installed
between blocks and four extensometers, two electrical
joint meters, a pendulum and a flow meter to measure
the seepage flow.
The result has been satisfactory up to the present.
The maximum seepage recorded was 158.4 l/min

8. TECHNICAL FEATURES
General Location
River
Pelotas
Basin
Uruguay River
Municipalities
Right bank
Anita Garibaldi
Left bank
Pinhal da Serra
States
Santa Catarina and Rio Grande do Sul
Latitude
27 46' South
Longitude
51 13' West
Beginning of construction
June 2001
End of construction
October 2005
Catchment area
13,000 km
Mean annual temperature
16.5 C

Mean annual rainfall

1,788 mm
Owner
BAESA ENERGTICA S.A.
Design and construction
Basic and detailed design ENGEVIX Engenharia S.A.
Construction and erection
Camargo Correa
Comrcio e Construes S.A
Supplies:
Electromechanical equipment
Alstom Brasil
Substation and transmission lines
ENGEVIX
Engenharia S.A.
Reservoir
Area at Max. Normal Water Level
Storage at Normal Water level
Storage at Minimum Water level
Max. Normal Water Level
Max. Flood Level
Minimum Water Level
Length
Width
Tailrace
Max. Normal Water Level
Minimum Water Level
Flows
Max. Mean daily inflow
Max flow recorded July/1992
Minimum daily flow recorded
Mean long term flow
Dam
Type
Maximum height
Length
Width at the crest
Crest elevation

92 km
5,000 hm
2,286 hm
647.0 m
649.17 m
617.0 m
120 km
600 m

480.0 m
478.5 m

292.4 m/s
10,421 m/s
May/1952 18.8 m/s
292.4 m/s

CFRD
185.0 m
665.0 m
10.0 m
651.0 m

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Main Brazilian Dams III

Spillway
Type
Maximum discharge capacity
Crest elevation
Length
Maximum specific discharge

surface (ski jump)

23,840 m/s
627.0 m
119.4 m
233.9 m/s

Gate
Number of gates
Gate height
Gate width

6
20.98 m
15.0 m

Intake
Height
Length
Crest elevation

52.3 m
24.3 m
651.0 m

Gates
Type
Number of gates
Gate height
Gate width
Diversion
Type
Dimension
Length
Power Tunnel
Type
Number
Internal Diameter
Length
Reinforced stretch
Powerhouse
Type
Height
Length

fixed wheel gates

6
6.54 m
6.2 m

2 Tunnels
15.0 m (wide) x 17.0 m (high)
816.0 and 920.0 m

indoor
3
6.9 m
309.2 m
177.1 m

indoor
45.0 m
91.8 m

Turbines
Type
Quantity
Rated power
Rated flow
Operating speed
Manufacturer
Generators
Type
Rated capacity
Voltage
Frequency
Operating speed
Power factor
Manufacturer
Step-up Transformers
Type
Number
Rated power
Voltage
Frequency
Manufacturer
Substation
Type
Rated voltage

FRANCIS - vertical shaft

3
236 MW
165 m/s
200 rpm
ALSTOM

Vertical shaft
245 MVA
16 kV
60 Hz
200 rpm
0.95
ALSTOM

3+1
245 MW
230 kV
60 Hz
ALSTOM

Conventional
230 kV

The main volumes of civil works are as follows:

Earth excavation
2,000,000 m
Rock excavation
10,000,000 m
Tunnel excavation
470,000 m
Rock fill and transition
12,000,000 m
Concrete
330,000 m
Reinforcement
14.000 tons

9. BIBLIOGRAPHY
[1] J. Barry Cooke - Concrete Face Rockfill Dams:
Volume - CFRD 2000 - Beijing, China - 2000.

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