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On February 6, 1994, a large debris flow developed because of intense rains in a 800-m-high mountain range called Serra do Cubatão, the local name for the Serra do Mar, located along the coast of the state of São Paulo, Brazil. It affected the Presidente Bernardes Refinery, owned by Petrobrás, in Cubatão. The damages amounted to about US $40 million because of the muck cleaning, repairs, and 3-week interruption of the operations. This prompted Petrobrás to conduct studies, carried out by the authors, to develop protection works, which were done at a cost of approximately US $12 million. The paper describes the studies conducted on debris flow mechanics. A new criteria to define rainfall intensities that trigger debris flows is presented, as well as a correlation of slipped area with soil porosity and rain intensity. Also presented are (a) an actual grain size distribution of a deposited material, determined by laboratory and a large-scale field test, and (b) the size distribution of large boulders along the river bed. Based on theory, empirical experience and backanalysis of the events, the main parameters as the front velocity, the peak discharge and the volume of the transported sediments were determined in a rational basis for the design of the protection works. Finally, the paper describes the set of the protection works built, emphasizing their concept and function. They also included some low-cost innovative works.

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