THE PRODUCTION OF THE COMPACTED EMBANKMENT FROM

BELO MONTE HPP

Oscar M. Bandeira *, Marcelo L. Foz † Daniel T. Leite ‡ , Marcelo B. Boaventura §,
Leandre S. Valino **, and Rodrigo J. F. Sarlo ††.

* Norte Energia S.A.

SCN, Quadra 04 – Bloco B, salas 904 e 1004 – Centro Comercial Varig
CEP 70714-900 - Brasília, Brasil
e-mail: [email protected], webpage: www.norteenergiasa.com.br

Keywords: Embankment Dams, Fill, Compaction.

Abstract. The achievement of producing about 60 million m³ of compacted embankment

in just 3.5 years, in the Amazon region, where challenges with weather, logistics due to
distances, environmental problems, among others, to allow the construction of the 36
dams / dikes of the Belo Monte HPP has been overcome.
The purpose of this article is to present a summary of the technical characteristics of
Belo Monte HPP, as well as to present the main challenges faced during the execution of
the compacted embankment, along with the characteristics of the soil materials, the
equipment used for compaction. In addition, to present the results obtained in the
Technological Control, besides of the control procedures used to verify the quality of
these embankment during its construction.

1 INTRODUCTION
The reservoir of the Belo Monte HPP has two sectors interconnected by a channel, called
the Diversion Channel: a sector, upstream of the Diversion Channel, formed by the natural
course of the Xingu River, called the Main Reservoir, and another sector downstream, formed
by the construction of dams and dikes, called the Intermediate Reservoir.
The Adduction to the main Intake in the Belo Monte Site, from the natural course of the
Xingu River, is made through the Diversion Channel, seven Transposition Channels
denominated CTPT1, CTPT2, CTPT3, CTTC, CTCA, CTCS and CTSA and three Filling
Channels denominated 1, 2 and 3. The channels were excavated along the Intermediate
Reservoir in order to reduce the load losses.
For the most part, the Diversion Channels comprised excavations in soil, with lateral
slopes below the operation levels of the Intermediate Reservoir. The channels were coated in
the bottom with rocking and in some of them, the protection extends to the lateral slopes.

†
CCBM.
‡
Norte Energia S.A.
§
Norte Energia S.A.
**
CCBM.
††
CCBM.

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 Oscar M. Bandeira, Daniel T. Leite, Marcelo B. Boaventura, Marcelo L. Foz, Leandre S. Valino and
Rodrigo J. F. Sarlo

Figure 1: General arrangement of Belo Monte HPP.

The Intermediate Reservoir consists of 28 containment dikes that closes saddles or streams
thalweg and are distributed along the entire reservoir. In addition to these dikes, in the Belo
Monte region, the reservoir is limited by the Versant of the Santo Antonio Dam (VSAD), the
Left Closing Dam (LCD) and the Right Closing Dam (RCD), and the Intake in itself.

Figure 2: General arrangement of dikes and dams in the Intermediate Reservoir.

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 Oscar M. Bandeira, Daniel T. Leite, Marcelo B. Boaventura, Marcelo L. Foz, Leandre S. Valino and
Rodrigo J. F. Sarlo

2 CHARACTERISTICS OF THE INTERMEDIARY RESERVOIR DIKES

The dikes have a homogeneous section in compacted soil and were constructed with
colluvial soils and residual migmatito soils from the borrow areas located, in the great
majority, within the area now flooded by the reservoir, minimizing the environmental impact.

Figure 3: Typical Section of Intermediate Reservoir Dikes.

Under the upstream backrest, a trench exploratory/insulation was carried out in order to
investigate, mainly, the occurrence of canaliculi. Its depth was, in principle, established at
3.00 m, with the possibility of deepening it to 6.00 m, depending on the frequency and
magnitude of the canaliculi. The trench was also provided with the launching of a layer of
sand on its downstream slope, in order to prevent the transport of fines through the smaller
canaliculi. In the trench was also planned the treatment of canaliculi by means of injection of
cement by gravity.
The internal drainage system consists of a 0.70 m wide vertical sand filter and, on the
foundation, a horizontal drainage mat of 3 or 5 layers of granular materials, with protection at
the outlet downstream, a foot drain fitted with transitions and rocking.

3 CONSTRUCTIVE ASPECTS
Table 1 shows the dynamics of the construction of the compacted embankment in the
Intermediate Reservoir, with 46 million m³, which corresponds to 76.6% of the total volume
executed in the whole project (60 million m³). It is noticed that in the first two years of the
work, the advance was limited to about 22% and that 78% of the embankment were built in
the last 2 years.
The difficulty of advancing in the first 2 years of construction may be justified by the
following factors: (i) challenging logistics, (ii) implementation and adaptation of access roads
to the sites, (iii) implantation of pioneer sites, (iv) implantation of definitive sites, (v)
liberation of the areas to start construction of the structures - environmental, land ownership,
archaeological prospecting, plant suppression, etc.
As for the logistics challenge, just remember that Belo Monte HPP is located on west of
Pará, in the municipality of Vitória do Xingu, distant about 50 km from the city of Altamira.
Access can be made via land via the Transamazônica Highway (BR-230), via river from
Belém to the city of Vitória do Xingu and by air.
In order to make feasible the construction of the Belo Monte Hydroelectric Plant, four
construction sites were implanted: Belo Monte Site (Main Powerhouse), Pimental Site

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 Oscar M. Bandeira, Daniel T. Leite, Marcelo B. Boaventura, Marcelo L. Foz, Leandre S. Valino and
Rodrigo J. F. Sarlo

(Complementary Powerhouse and Xingu River Bus), Diversion Channel and Bela Vista Site
(Dikes Construction of Intermediate Reservoir). To get a sense of the size of the work, it
should be noted that the distance between the Belo Monte Site and the Pimental Site is about
50 kilometers, a distance that is repeated between the Belo Monte Site and the Diversion
Channel.
From the Transamazônica Highway (BR-230), the beds are accessed by the Travessão 27
and Travessão 55 (vicinal roads) meaning more than 80 kilometers of roads. The works of
adaptation of Travessão 27 were initiated after the release of the Installation License in June
2011 and the works of adaptation / implementation of Travessão 55 were started in 2012.

Anual Volume Reached (m³)

Structure Total
2012 2013 2014 2015
VSAD 1.022.180 3.572.992 1.435.421 6.030.593
RCD 124.857 737.872 412.717 1.275.446
LCD 326.396 3.440.271 3.853.984 229.705 7.850.356
Dike 1 5.120 5.120
Dike 1A 40.233 100.589 140.822
Dike 1B 5.972 5.972
Dike 1C 140.753 703.713 844.466
Dike 6A 147.719 91.354 781.148 1.020.221
Dike 6B 16.611 1.156 18.345 36.112
Dike 6C 712.455 1.892.062 1.529.887 4.134.404
Dike 7B 454.943 1.331.741 1.786.684
Dike 8A 1.604.557 3.623.228 5.227.785
Dike 8B 352.992 1.511.578 1.864.570
Dike 10B 185.935 33.799 219.734
Dike 11 154.063 154.063
Dike 12 4.642 4.642
Dike 13 1.659.723 2.825.264 1.272.674 5.757.661
Dike 14A 52.811 350.883 926 404.620
Dike 14B 34.954 34.954
Dike 14C 197.403 1.735.181 631.917 2.564.501
Dike 14D 68.052 200.249 190.045 458.346
Dike 14F 138.617 21.426 160.043
Dike 14G 15.350 1.903 17.253
Dike 18 78.609 12.893 1.688 93.190
Dike 19B 769 1.718.443 831.292 1.611.325 4.161.829
Dike 19C 15.504 4.559 20.063
Dike 19D 2.095 60.688 62.783
Dike 19E 39.811 39.811
Dike 27 62.647 62.647
Dike 28 284.673 28.426 1.195.680 1.508.779
Dike 29 32.895 174.974 207.869
TOTAL 327.165 9.726.173 19.136.663 16.965.338 46.155.339
Table 1: Anual Volume of Compacted Embankment.

As the implantation of the sites and the access roads advanced, the works of land and rock
also advanced. In 2012 the activities of common excavation, foundation treatment and
construction of embankments of dikes and dams was still incipient. In 2013, the advance of

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 Oscar M. Bandeira, Daniel T. Leite, Marcelo B. Boaventura, Marcelo L. Foz, Leandre S. Valino and
Rodrigo J. F. Sarlo

the compacted embankment was indeed relevant, reaching the mark of 9.7 million m³, about
21% of the total.
At the beginning of 2014 there was a major challenge ahead: the execution of 36 million
m³ of embankment in just 2 years. The schedule of the work provided for the beginning of the
filling of the Intermediate Reservoir was 11/15/15. At the time, taking into account the
existing difficulties, the climate was skeptical about the viability of these large volumes in
such a short period of time. The objective of this article is to present a brief description of the
actions taken during the years 2014 and 2015 to enable the construction of 36 million m³ of
compacted embankment of the dikes and dams of the Intermediate Reservoir in such short
term.

4 THE EQUIPMENT AND LABOUR RESOURCES

Labor and equipment resources, can undoubtedly be considered, as one of the important
factors that enabled the accomplishment of the goal of construction of compacted
embankment. By 2014, at the peak of the project, approximately 37,000 employees and 5,400
units were directly involved in the construction of the Belo Monte HPP
The training of local labor was also a defining characteristic of the work. The Capacitar
Program was an initiative of the Belo Monte Constructor Consortium (CCBM), which
promoted training of new professionals from the surrounding municipalities. About 14,000
professionals were trained and more than 10,000 were admitted by the Constructor
Consortium to work on the sites of the hydroelectric plant.

5 EQUIPMENT AND TECNOLOGICAL INCREMENTS

The acquisition of a fleet of new equipment, with high technology resources, played an
essential role, contributing to the achievement of production world records. With the support
of the world's leading equipment manufacturers, the equipment has gone through a world-
class maintenance process, with well-structured workshops and even laboratories for lubricant
analysis. Remote monitoring of operating conditions using applications such as Caterpillar /
Trimble, VisionLink and Mercedes-Benz Fleetboard is also noteworthy.
The Smartcargo, heavy equipment fleet monitoring and control system, and Simova's
ConstruMobil electronic sewer system were also used for the purpose of: (i) optimizing
production; (ii) increase productivity of equipment; (iii) reduce maintenance costs and other
overheads.
The equipment used for compaction of embankment sites had a heavy weight (CAT 825H
32,7 t and CT300 Dynapac 21 t compactor roller), high power traction, which could reach
speeds of up to 15.6 km/h (CAT 825H) and 21 km/h (Dynapac CT300). The higher
weight/higher velocity combination, thus applying higher energy, allowed the increase of the
thickness of the compacted layers. The definition of the compaction parameters took into
account the definition of the translucency velocity of better yield, which did not overturn the
surface soil layer and did not detract from the increased densities.
The grids used to homogenize the released soil, also underwent a process of tests and
evaluation in experimental tracks. From the obtained results, it was possible to increase
improvements that guaranteed the effective treatment of the layers of launched soil, having as
main gain the increase of the dimensions of the discs.
The use of articulated off-road truck (type CAT 740B) in the common excavation and
cleaning of the foundation of the structures, also deserves attention. This equipment allowed
the work to be advanced in areas of difficult access, minimizing the need to construct service

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 Oscar M. Bandeira, Daniel T. Leite, Marcelo B. Boaventura, Marcelo L. Foz, Leandre S. Valino and
Rodrigo J. F. Sarlo

accesses, both in the excavation regions and in the material disposal regions (Dumping
Ground). Another important differential in this equipment was its capacity of material
transport, about 23 m³, which guaranteed a considerable increase of productivity.

Figure 4: Equipment utilized on the compacted embankment constructions.

6 SUPPORT AVAILABLE IN THE CONSTRUCTION SITE

The basic criterion adopted in the planning and implementation of the four sites at the Belo
Monte Hydroelectric Plant was to provide adequate accommodation to workers, which
included the provision of essential services and care for the quality of life of the people
involved. The implantation of housing in the construction sites minimized the anthropic
impacts in the region, avoiding the daily transport of large contingents of workers in the route
between the city of Altamira and the construction sites.
The camp building sector had the following main constructions: (i) concierge/control, (ii)
kitchen/canteen, (iii) housing, (iv) parking, (v) medical outpatient clinic, (vi) industrial and
collective laundries, (vii) coexistence and leisure center, (viii) school for adults and (ix)
infrastructure support - sewage treatment plant, wastewater treatment plant, landfill, waste
area, etc.
The industrial building sector has the following main constructions: (i) engineering offices,
(ii) ambulatory, (iii) parking, (iv) warehouse, (v) mechanical workshop, (vi) gas station (viii)
carpentry center, (ix) concrete plant and (x) crushing plant.

7 ITINERANT SUPPORT
In 2014, the embankment project progressed simultaneously in 17 structures, increasing to
25 structures by 2015, with the challenges of personnel logistics, equipment and supplies for
these works scattered over an extension of more than 30 kilometers.
In the service fronts, several types of support were required: (i) canteens, (ii) rest areas,
(iii) sanitary facilities, (iv) electrical maintenance, (v) mechanical maintenance, (vi)
topography, (viii) laboratory tests, etc.
An important differential of the execution of the embankments of the dikes and dams was
the "itinerant" support present in the work. At the height of the project, in addition to the three
central canteens in the main sites, there were five more air-conditioned mobile canteens
scattered around the building, which optimized the movement of employees.

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 Oscar M. Bandeira, Daniel T. Leite, Marcelo B. Boaventura, Marcelo L. Foz, Leandre S. Valino and
Rodrigo J. F. Sarlo

The same happened with laboratory tests for the technological control of the construction
of compacted embankment, the results of which were obtained quickly in one of the 10 labs
(4 central and 6 roving) strategically positioned throughout the work. A quality control
system, therefore, was structured to meet the demands of large volumes of compacted
embankment and productivity challenges.
The same itinerant concept was applied to the other demands of the work: (i) topography,
(ii) construction maintenance, (iii) electrical maintenance and refrigeration, (iv) mechanical
maintenance, (v) The support structures were repositioned whenever necessary, to meet the
dynamics of the enterprise.

8 TECNOLOGICAL CONTROL
The following will briefly describe some points considered relevant to obtain the good
results observed in the execution and the release of the embankment layers of dikes and dams,
as far as Technological Control.

8.1 Technological Control Data Management Web Tool (AutoLab)

 Through the use of the AutoLab management software, the release of the squares gained
agility, since all the data were inserted directly in the program and it provided, just in
time, the results of the tests of degree of compaction and humidity deviation, and it is
not necessary for the laboratory to draw graphs and make interpolations.
 The implementation of the management program also allowed an adequate control of
the data of the execution of the layers. From the analysis of the reports generated by the
system it was possible to:
 Identify the occurrence of layers rework, their frequency and even the responsible in
charged for the squares where the deviations occurred;
 Establish more targeted training to correct identified deviations;
 Definition of constructive methods and standardization of activities;
 Obtaining the ideal number of passes for each roller model used in embankment;
 Correlate the results of rejected materials by moisture deviation, outside the specified
limit, with the places of origin of the material (deposits);
 Treat data in real time, ensuring greater reliability of results.

8.1 Compression control

The values of the degree of compaction were on average 98.0%, with standard deviation
around 1.5%. The results of the top/base control of the layers also showed compaction
difference, from top to bottom, around 1.0 to 1.5%.

9 OPERATIONAL EXCELLENCE
In order to promote a coordination of the lean production system, based on the philosophy
of the Toyota production system, the NEO - Operational Excellence Nucleus - dedicated to
the compacted embankment program was implemented in 2013. From this work was
established the pull planning, as well as the ideal rhythm of work, in order to avoid wastes,
overproduction, stocks and rework. Among the various actions, highlights:
 Definition of the ideal size of workplaces due to the sequencing of activities;
 Balancing resources per work place according to the ideal size of each lot;

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Oscar M. Bandeira, Daniel T. Leite, Marcelo B. Boaventura, Marcelo L. Foz, Leandre S. Valino and
Rodrigo J. F. Sarlo

Figure 5 - Definition of workplaces.

 Implementation, inside the compartment of the roller, of a device to control the number
of passes, reducing the occurrence of overcoating of layers or lack of compaction;
 Creation of equipment patrols - a group of trucks dedicated to a bulldozer - associated
to the definition of the origin and destination of the materials - deposit / launching place
- guaranteeing the production rate (Time Takt);

Figure 6 - Identification between transportation equipment and load equipment.

 Standardization of truck load maneuvers in the fields;

 Standardization of the width of access platforms, both the entrance and exit of
workplaces, as well as deposits and dumping sites;

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Oscar M. Bandeira, Daniel T. Leite, Marcelo B. Boaventura, Marcelo L. Foz, Leandre S. Valino and
Rodrigo J. F. Sarlo

Figure 7 - PCS (Problem / Cause / Solution) of accesses.

 Signaling of accesses and visual identification of workplaces;

 Implementation of a training and monitoring program for drivers in training, with the
participation of multipliers (more experienced drivers);

Figure 8 - Operational Development Training based on NR 11 – Excavator.

 Implantation of support points close to the service fronts aiming to reduce the time of
displacement of the teams;
 Reduction of the spacing between the layer thickness indicators in the launching areas,
as well as the use of reflective adhesives on the crossbars, improving their visualization
and their effectiveness during the nightshift.

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Rodrigo J. F. Sarlo

10 CONCLUSION
The filling of the Intermediate Reservoir at the end of 2015 was only possible with the
completion of compacted filling of the dikes and dams, which moved an impressive 46
million m³, almost 80% of this volume during the last two years. Challenges encountered in
the first years of the project's implementation involved environmental issues, expropriation
and clearing of areas, archaeological surveys, advances in plant suppression, highlighting the
enormous difficulty of logistics, great distances and poor access conditions.
Enabling the implementation of large volumes of compacted embankment required a series
of coordinated actions that included labor training, acquisition of a fleet of new equipment,
state-of-the-art technology, support from major equipment manufacturers, use of remote
monitoring of operational conditions, electronic appropriation system, etc.
The construction of the Belo Monte Hydroelectric Plant counted with a good infrastructure
in its four construction sites, which had two main core: accommodation and industrial.
However, the great differential observed in the execution of the compacted embankment was
the concept of itinerant support, which allowed a rapid repositioning of the resources to meet
the dynamics of the work.
AutoLab management software has established itself as a great ally of the procedures
related to technological control, an indispensable item in the quality of compacted
embankment. In addition to gaining agility in obtaining test results, the program ensured an
adequate control of landfill layer data, reducing rework, allowing targeted training, pointing
to the need to define constructive methods and standardization of activities, among other
important gains.
The creation of the Operational Excellence Nucleus (NEO), dedicated to the compacted
landfill program, constituted an essential action to obtain the results presented in this article,
as it avoided waste, overproduction, stocks and rework. The definition of the ideal size of the
squares, the balance of resources per square, the creation of equipment patrols, the
standardization of service maneuvers are examples of the effectiveness of NEO.

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