EP2055457A2 - Method for producing a concrete building block and device for carrying out the method - Google Patents

Abstract

The method involves filling a layer of concrete (3) with lower density into a mold (8). Concrete with lower density is filled between an upper side of concrete (2) with higher density and an upper edge (9) of the mold after sedimenting the concrete with higher density, where two layers of concrete with lower density form an upper side and a lower side of a building block. The upper side and the lower side of the building block are machined mechanically such that the building block is arranged in a dimensionally accurate manner. An independent claim is also included for a device for manufacturing a building block.

Description

The invention relates to a method for producing a building block from at least two types of concrete with different densities. The invention also relates to a device for carrying out such a method.

From the EP 0 960 989 B1 is a method for producing a block of concrete, in particular a formwork or block, known for the construction of structures.

From practice it is also known that building blocks made of concrete must meet a high dimensional accuracy and this is generally achieved by mechanical post-processing. This applies in particular to plan stones and dry formwork or block stones. The mechanical finishing is done by milling or grinding.

To a milling of the block with conventional tools such. B. carbide, a concrete with a low density, such. B. lightweight concrete. A disadvantage of lightweight concrete, however, is that it has a lower strength and hardness in the processed state in the building, such as normal concrete or heavy concrete. However, the use of normal or heavy concrete is not suitable if the module has to be mechanically reworked, because the normal or heavy concrete can no longer be reasonably processed with carbide tools or the like due to its hardness. For the processing of normal concrete or heavy concrete diamond tools are generally necessary, which cause high costs and a low processing speed.

One solution to this problem is from the EP 0 960 989 B1 known. That from the EP 0 960 989 B1 Known method allows the production of a building block of heavy concrete, which is provided on a top or bottom with a layer of lightweight concrete. The module thus has a high strength and can still be reworked mechanically on the provided with the lightweight concrete side, including conventional tools such. B. of carbide are sufficient or with diamond tools a sufficiently fast processing is possible.

The production of a building block according to EP 0 960 989 B1 takes place in that in a first process step, the concrete with the high bulk density (heavy concrete) is filled into a mold up to the area of its upper edge and shaken. After shaking off the concrete, a concrete with a lower bulk density (lightweight concrete) is filled between the top of the concrete with the high bulk density and the top edge of the mold. The low density concrete forms the top or bottom of the building block. So that the block can be installed accurately, the top or bottom of the block formed by the concrete with the lower density is processed mechanically, preferably by milling or grinding.

That according to the EP 0 960 989 B1 provided complete backfills of the mold up to its upper edge with a heavy concrete leads to a uniform filling of the mold, so that the heavy concrete, after this has settled by the shaking, has an at least approximately flat surface or an equal thickness / thickness. This makes it possible for the second Layer of lightweight concrete with a uniform / constant thickness can be filled to the top of the mold.

The procedure according to EP 0 960 989 B1 allows the production of a building block with a top or bottom made of lightweight concrete, without the block must be tilted, as in the prior art, for example, the method according to FR 1 521 840 A , was necessary.

In the method of the EP 0 960 989 B1 For the manufacture of concrete building blocks it is envisaged that the mold in which the building blocks are produced is open both at the top and at the bottom. The lower opening is normally closed by a highly accurately manufactured pallet, for example a steel pallet, so that on the one hand concrete can not escape during the filling of the mold and on the other hand the underside of the building block achieves a high degree of dimensional accuracy.

However, there are also known methods for producing blocks of concrete, in which the bottom of the mold is closed by a simple wooden pallet or the like. Although this is cheaper compared to a steel pallet, the underside of the components does not receive the same high dimensional accuracy as a steel pallet.

The present invention has for its object to provide a method for producing a block of concrete, through which the block is inexpensive to produce, has a high hardness and strength and can be reworked inexpensively.

This object is achieved by the features of claim 1. An apparatus for carrying out the method results from the features of claim 16

The fact that in a first process step, a layer of a concrete is filled with a lower density in a mold, the block also receives on the side, which is formed by the bottom of the mold or the pallet, a surface or layer with conventional tools, eg. B. hard metal, can be mechanically reworked. The use of expensive diamond tools is thus avoided and their long processing time significantly reduced.

On the applied in the first process step layer of a concrete with a lower density is then filled in a second process step, a concrete with a higher density in the form to the region of its upper edge. By filling the concrete with the higher bulk density up to the area of the upper edge of the mold becomes a uniform Backfilling and thus achieved a substantially uniform thickness / thickness of the layer of the concrete with the higher density. Already during the filling of the concrete with the higher bulk density or preferably afterwards it can be vibrated and / or stamped. After the concrete settles by shaking and / or stamping, in a third process step, the lower density concrete is filled between the top of the higher bulk density concrete and the top of the mold. Thus, on two opposite sides forming the top and bottom of the building block, the building block receives a layer of lower density concrete which can be easily and inexpensively machined so that there is a top and bottom surface high dimensional accuracy is achievable.

The lower density concrete at the top and bottom, respectively, need not be the same concrete, the only difference is that the concrete has a lower bulk density than the concrete used between the top and bottom of the building block ,

The high dimensional accuracy of the device is achieved in a fourth process step by a mechanical processing of the top and bottom of the block, so that the block are accurately laid can. The mechanical processing of the top and the bottom is preferably carried out by milling and / or grinding.

For milling or grinding the top and bottom of the block known from the prior art methods can be used. According to the invention can be provided both that the top and bottom of the block is milled or ground simultaneously, as well as that first one side is processed and the block is then pivoted by 180 °, so that the other side can be edited.

The fact that the block is made of concrete with different densities and thus resulting in different properties, the respective advantageous features of different types of concrete can be used accordingly. A concrete with a high bulk density gives the component a high hardness and strength as well as a high weight. In addition, concrete with a high density, such. As normal or heavy concrete, cheaper than a concrete with a lower density, such. B. lightweight concrete. The low density concrete ensures cost-effective reworking.

The solution according to the invention makes it possible, even if the building blocks have a mold or mold inserts are produced, which are sealed at its bottom by wooden pallets, which can be provided on the wooden pallets adjacent side of the block in a simple and cost-effective manner with a high dimensional accuracy.

As the inventors have found, the high strength and hardness of the building block resulting from the high density concrete is not adversely affected by the building block having a layer of lower density concrete both at the top and at the bottom.

It is advantageous if the block is made in an embodiment as block or formwork stone at least 90% - based on its volume - from the concrete with the higher density.

In an alternative embodiment of the block as a hollow block, a part, preferably the complete bottom and the exposed tops of the webs of lightweight concrete can be produced. If the floor, with a thickness of preferably up to 50 mm, is completely made of lightweight concrete, the lightweight concrete content of the hollow block can increase up to 50%, since the land area is generally only 20% concrete and 80% air cavity. The bottom of the hollow block forms only during its production, the bottom of the block or borders to the pallet through which the bottom of the mold is formed. In a known manner, the bottom or the closed bottom surface of the hollow block forms the top, when the hollow block is installed.

According to the invention, it may further be provided that the concrete with the lower bulk density in the first method step is only filled into the mold as a thin layer. The layer may, for example, have a thickness of 0.5 to 5 cm, preferably 1 to 3 cm.

It is advantageous if the filled in the first process step concrete is shaken with the lower density before performing the second process step and / or stamped. By shaking and / or stamping a better / more stable base for applying the concrete with a higher bulk density is created. It is also avoided that the concrete with the lower bulk density is displaced by the introduction of the concrete with a higher bulk density.

According to the invention, it can further be provided that the component is shaken and / or stamped after the third method step. As a result, the block is compressed or pressed and solidified.

It is advantageous if the concrete with the lower density in the first process step is filled by means of a filling at least approximately evenly or even and with a constant thickness / thickness in the mold.

Uniform filling of the mold with the lower density concrete to be introduced in the first process step can be achieved, for example, by moving the filling device over an upper opening of the mold and filling concrete into the mold during the movement of the filling device. It can be provided that the movement of the filling device is synchronized with the delivery of concrete in such a way that the mold is filled with an at least approximately uniformly strong or thick layer of the concrete with the lower density.

In a particularly advantageous apparatus for carrying out the method, in particular for carrying out the first method step of the method, a filling device is formed, which is movable at a defined speed over an upper opening of a mold to be filled, wherein the filling device has dispensing means or discharge members during the movement of the filling device dosed to spend concrete in the mold.

The use of known filling carriages, which are open on their underside and are moved over rollers or rails over the upper opening of the mold, is unsuitable for forming a uniform thin layer on the bottom of the mold or the pallet forming the bottom of the mold to raise. Although the charging car can be filled with an intended amount of concrete, but as soon as the leading edge of the open bottom of the filling carriage has reached the open top of the mold, the concrete contained in the filling car falls uncontrollably, in particular heaped, into the mold. A uniform distribution of the concrete or a uniform formation of the lower layer can not be achieved. Therefore, it can be provided according to the invention that the movement of the filling device is synchronized with the dispensing means in such a way that at least approximately uniformly concrete with the lower bulk density is filled into the mold in the first method step. A particularly preferred embodiment of the filling device results from the fact that the output means are designed as a conveyor belt. By a conveyor belt, it is possible in a simple manner to continuously drop concrete into the mold. A conveyor belt also allows for an advantageous feeding of the concrete, which is present as a spilled material.

In a further advantageous embodiment, the output means may be formed as a vibration unit, which ensures that concrete gets into the mold continuously and evenly through an appropriate vibration. The filling device with the vibration unit may preferably be formed as a vibrating trough, whereby a uniform, continuous delivery of the concrete is ensured.

In the first method step, the concrete with the lower bulk density can be particularly preferably introduced as a thin layer into the mold when the filling device is first moved from a trailing edge of the upper opening of the mold to a front edge. The output edge of the conveyor belt can be positioned approximately flush with the front edge of the upper opening of the mold. During a subsequent return movement of the filling device from the front edge to the trailing edge of the upper opening of the mold, concrete can be filled or filled into the mold by a synchronized movement of the conveyor belt or a vibration of the vibrating unit.

Preferably, the conveyor belt can move forward at the same speed that the filling device moves back. The conveyor belt can preferably be designed as a circulating conveyor belt.

Of course, the filling device provided with a conveyor belt or a vibration unit be operated in other ways to achieve a metered introduction of concrete into the mold. It is conceivable z. Also, for example, the conveyor or vibratory unit conveys concrete into the mold as the filling device moves from a trailing edge of the mold's top opening to a leading edge.

In a development of the invention, it can further be provided that the filling device or its dispensing means / dispensing member is supplied with concrete by a conventional filling device, which also fills the previously known filling car.

It is advantageous if, with the method according to the invention, a mold is filled which has a plurality of mold inserts which are each designed to form a building block.

It can be provided that the mold has two to thirty, preferably two to twenty, mold inserts, which are filled in each process step. The number can be varied depending on the size of the blocks to be produced.

It is also advantageous if the components produced according to this are mechanically reworked together.

Simultaneous production of several components or simultaneously filling of a plurality of mold inserts per method step can easily be achieved by suitable dimensioning of the filling device, the filling carriage, the means for shaking the molds or the compressor units (eg stamps) and the like.

Advantageous embodiments and developments of the invention will become apparent from the other dependent claims.

An exemplary embodiment of the invention is shown in principle below with reference to the drawing.

Fig. 1

eine Prinzipdarstellung des erfindungsgemäßen Verfahrens mit einer Form die zwei zu befüllende Formeneinsätze aufweist;

Fig. 2

eine Darstellung gemäß Fig. 1, wobei sich die Einfülleinrichtung an einer Vorderkante einer oberen Öffnung der Form befindet;

Fig. 3

eine Darstellung gemäß Fig. 1, wobei die Form mit einer Schicht aus Beton mit einer niedrigeren Rohdichte befüllt ist;

Fig. 4

eine Darstellung gemäß Fig. 3, wobei zusätzlich eine Schicht aus Beton mit einer höheren Rohdichte in die Form eingebracht ist;

Fig. 5

eine Darstellung gemäß Fig. 4, wobei durch Rütteln und/oder Stempeln der Beton so verdichtet wurde, dass sich dieser gesetzt hat;

Fig. 6

eine Darstellung gemäß Fig. 5, wobei in den durch das Stempeln und/oder Rütteln frei gewordenen Bereich zwischen der Oberseite des Betons mit der höheren Rohdichte und der Oberkante der Form ein Beton mit einer niedrigeren Rohdichte aufgefüllt wurde;

Fig. 7

eine Darstellung gemäß Fig. 6 während dem Stempeln des Bausteins nach Durchführung des dritten Verfahrensschritts; und

Fig. 8

eine vergrößerte Darstellung eines fertigen Bausteins, welche an seiner Oberseite und Unterseite eine Schicht aus Beton mit einer niedrigeren Rohdichte aufweisen, wobei prinzipmäßig eine Fräseinrichtung dargestellt ist, welche den Baustein bereits an seiner Oberseite und Unterseite mechanisch nachbearbeitet hat.

It shows:

Fig. 1

a schematic representation of the method according to the invention with a mold having two mold inserts to be filled;

Fig. 2

a representation according to Fig. 1 wherein the filling device is located at a front edge of an upper opening of the mold;

Fig. 3

a representation according to Fig. 1 wherein the mold is filled with a layer of concrete of a lower density;

Fig. 4

a representation according to Fig. 3 wherein additionally a layer of concrete with a higher bulk density is introduced into the mold;

Fig. 5

a representation according to Fig. 4 where, by shaking and / or stamping, the concrete was compacted so that it has settled;

Fig. 6

a representation according to Fig. 5 wherein, in the area vacated by the stamping and / or shaking, between the top of the higher bulk density concrete and the top of the mold, a lower density concrete has been filled;

Fig. 7

a representation according to Fig. 6 during stamping of the package after performing the third process step; and

Fig. 8

an enlarged view of a finished building block, which have on its top and bottom a layer of concrete with a lower density, in principle, a milling device is shown, which has already machined the block on its top and bottom mechanically.

Fig. 8 shows a block 1 produced by the process according to the invention for the production of buildings. In the exemplary embodiment, the block 1 is formed as a block or shuttering block. The module 1 is formed from a concrete 2 with a high or higher density and a concrete 3 with a low or low density. The concrete 2 with the higher bulk density in the exemplary embodiment is a heavy concrete, for example a concrete with a quartz content and / or a proportion of gravel. The lower density concrete 3 is a lightweight concrete with a maximum weight of 1,400 kg / m ³ .

The outer walls of the module 1 are formed by a top 4, a bottom 5 and side walls 6. The upper side 4 and the lower side 5 of the module 1 are formed from the lightweight concrete 3. The layer between the top 4 and the bottom 5 (and thus the largest part of the side walls 6 of the block 1) is formed from the heavy concrete 2.

The top 4 and the bottom 5 made of lightweight concrete 3 can be machined with conventional tools 7, z. B. milled or ground. This measure makes it possible to produce a precisely shaped module 1 with a very high dimensional accuracy. Thus, in particular by this method dry laid blocks or formwork blocks are to be offset accurately.

In order to achieve the required accuracy of the component 1 by means of appropriate post-processing, it is generally sufficient if the layers consisting of the lightweight concrete are produced as thin layers with a thickness of approximately 10 mm +/- 5 mm. As a result, it is possible for the module 1, in particular in one embodiment, to be at least 90% (volume) of heavy concrete 2 as block or formwork brick. Due to the high proportion of heavy concrete with the corresponding strength and hardness can be realized with the building block 1 thin outer walls.

The module 1 can also be provided with a non-illustrated insulation, as is common, for example, formwork blocks.

Fig. 1 shows a basic structure for carrying out the method according to the invention. In the exemplary embodiment, a mold 8 has two mold inserts 8a for forming a respective component 1. In the form 8 and the mold inserts 8a light or heavy concrete can be filled to create a block 1 of at least two types of concrete with different densities. The mold 8 or the mold inserts 8 a each have an upper opening 9 and a lower opening 10. The lower opening 10 is in the embodiment closed by a transport pallet 11, for example made of wood. Also provided are vibration units 12 in order to shake the transport pallet 11 or the mold 8 and the introduced concrete 2, 3. Furthermore, stamp 13 are provided to stamp the introduced into the mold 8 concrete 2, 3 or to compress.

To fill the mold 8 two filling stations 14 are provided in the embodiment. The filling station 14 a is a conventional unit of a filling device 15 a, which is provided with a funnel to fill a filling carriage 16. After filling the filling carriage 16, the discharge opening of the filling device 15a can be closed. By means of rails or rollers, not shown, the filling carriage 16 can be guided along the upper side of the mold 8 so that concrete 2 can pass from the filling carriage 16 through the upper opening 9 into the mold 8 or the mold inserts.

The filling station 14b also has a filling device 15b with a funnel-shaped outlet and a closure mechanism. Instead of a filling carriage 16, however, a filling device 17 designed for metered delivery of concrete is provided. In the exemplary embodiment, the filling device 17 has a dispensing means designed as a conveyor belt 18, with which dispensed and uniformly poured concrete into the mold 8 can be introduced. The filling device 17 is analogous to the known filling carriage 16 so formed that it can be moved over the upper opening 9 of the mold 8 at a defined speed, for example via rollers or rails. During the movement of the filling device 17 via the upper opening 9 of the mold 8, the conveyor belt 18 delivers metered concrete, in the exemplary embodiment lightweight concrete 3, into the mold 8 or the mold inserts 8 a. The supply of the conveyor belt 18 of the filling device 17 via the filling device 15b.

Fig. 2 shows a position of the filling device 17 before the beginning of the filling of lightweight concrete 3 in the mold 8. For this purpose, the filling device 17 is first up to a front edge 9a of the upper opening 9, which defined in the embodiment of the filling station 15b farthest edge of the mold 8 , has been moved.

The filling device 17 serves to carry out the first (and the third) method step, after which a thin layer of the lightweight concrete 3 is to be filled into the mold 8.

Characterized in that the filling device 17 of the in Fig. 2 shown position back to the in Fig. 1 shown position, ie to the filling station 15 b, is moved and during this movement, the conveyor belt 18 synchronized lightweight concrete 3 via its output edge 18 a promoted (see arrow direction in Fig. 2 ), light concrete 3 passes uniformly into the mold 8 or the mold inserts 8 a. The lightweight concrete 3 falls on the transport pallet 11 and forms there a thin layer of 10 mm +/- 5 mm (see Fig. 3 ).

In the filling station 14b, a new amount of lightweight concrete 3 can again be applied to the conveyor belt 18. In the exemplary embodiment, it is provided that the filling device 15b in each case applies as much lightweight concrete 3 to the conveyor belt 18 as is necessary for carrying out a dispensing operation or a process step.

In the exemplary embodiment, it is optionally provided that, after carrying out the first method step and before carrying out the second method step, the introduced layer of lightweight concrete 3 is shaken and / or stamped. The vibration units 12 and the punches 13 serve this purpose.

Fig. 4 shows a representation after performing the second process step according to the invention, after which heavy concrete 2 in the mold 8 to the region of its upper edge (shown by the front edge 9a and trailing edge 9b) is filled.

For introducing the heavy concrete 2 is used in a known manner, the filling carriage 16, which may optionally be provided with a scraper to fill the mold 8 preferably exactly to the upper edge 9a, 9b.

After or optionally already during the filling of the heavy concrete 2 this can be shaken and / or stamped, to which in turn the vibration units 12 and the punch 13 can be used. By shaking and / or stamping the heavy concrete 2 is compressed, resulting in the in Fig. 5 picture displayed. The concrete 2 settles and condenses. The resulting clearance between the top of the concrete 2 and the top edge 9a, 9b of the mold 8 becomes, as in Fig. 6 recognizable, used to fill lightweight concrete 3. The filling of the lightweight concrete 3 is carried out analogously to the first process step. The filling device 17 may be provided in a manner not shown analogous to the filling carriage 16 with a scraper, so that the lightweight concrete 3 as exactly as possible to the top 9a, 9b of the mold 8 can be filled and also the surface is flat.

The applied in the third step lightweight concrete 3 is formed as a thin layer of 10 mm +/- 5 mm. The layers formed by the lightweight concrete 3 on the upper side 4 and the lower side 5 of the module 1 can basically have the same thickness.

Preferably, the filling of the concrete 2, 3 done so that the respective formed by the other concrete underlayer is still wet. This ensures that a firm and stable connection between the concrete layers is created.

After the complete filling of the lightweight concrete 3 is done as Fig. 7 shows, a compression of the two concrete layers 2, 3 by the punch 13 and optionally by using the vibration units 12. Thus, the concrete layers 2, 3 are compressed in their final stage and thus correspond to the dimensions of in Fig. 8 (enlarged) shown finished building block 1. The joint compaction creates a highly resilient connection between the different concrete layers.

As in Fig. 8 represented, the two layers of lightweight concrete 3, the top 4 and the bottom 5 of the block 1. The top 4 and the bottom 5 are mechanically processed in a fourth process step so that the block 1 can be installed dimensionally accurate. In the exemplary embodiment, the machining is carried out by means of a milling tool 7. Alternatively, a grinding tool or a similar method can be used. In the exemplary embodiment it is provided that the milling / grinding tool 7 first the bottom 5 of one or more procedurally manufactured building blocks 1 edited. Subsequently, the blocks 1 are turned over individually or together so that the milling / grinding tool 7 can also process the respective other side, in the present case the upper side 4.

Alternatively, two milling / grinding tools 7 can be provided, which allow a simultaneous or helical machining of the top 4 and the bottom 5 of the building blocks or 1.

The mold 8 shown in the embodiment has two mold inserts 8 a, which are each formed to form a module 1. Hereby only the basic principle is to be clarified. Preferably, in the individual method steps, in each case one mold 8 having a plurality of mold inserts 8a, preferably two to thirty, can be filled. The building blocks 1 produced thereafter can be mechanically reworked as simultaneously as possible.

Claims (15)

Method for producing a building block (1) from at least two types of concrete (2, 3) with different densities for constructing structures, the outer walls of the building block (1) being formed by a top side (4), a bottom side (5) and side walls ( 6), after which, in a first method step, a layer of a concrete (3) having a lower bulk density is filled into a mold (8), after which a concrete (2) with a higher bulk density is introduced into the mold (8) in a second process step. is filled and vibrated and / or stamped to the area of its upper edge (9), after which, after the concrete (2) has settled by shaking and / or stamping, in a third process step the concrete (3) is filled with the lower bulk density between the top of the higher density concrete (2) and the top (9) of the mold (8), the two lower density concrete layers (3) 4) and the underside (5) of the module (1) form, after which the upper side (4) and the lower side (5) of the module (1) is mechanically processed in a fourth process step, that the module (1) are installed dimensionally accurate can. Method according to claim 1,
characterized in that the upper side (4) and the lower side (5) of the module (1) is machined by milling and / or grinding. Method according to claim 1 or 2,
characterized in that the building block (1) is made in an embodiment as a block or shuttering stone at least 90% (volume) of the concrete (2) with the higher density. Method according to claim 1 or 2,
characterized in that the building block (1) is formed as a hollow block, wherein the bottom and the exposed upper sides the webs are made of lightweight concrete. Method according to claims 1 to 4,
characterized in that the concrete (3) is filled with the lower density in the first process step as a thin layer in the mold (8). Method according to one of claims 1 to 5,
characterized in that the concrete (3) is filled with the lower density in the third step as a thin layer on the concrete (2) with the higher density. Method according to claim 5 or 6,
characterized in that the thin layer has a thickness of 0.5 cm to 5 cm, preferably 1 cm to 3 cm. Method according to one of claims 1 to 7,
characterized in that the filled in the first process step concrete (3) is shaken with the lower density before performing the second process step and / or stamped. Method according to one of claims 1 to 8,
characterized in that is used as concrete (3) with the lower density lightweight concrete. Method according to one of claims 1 to 9,
characterized in that heavy concrete is used as the concrete (2) with the higher density. Method according to one of claims 1 to 10,
characterized in that the mold (8) has a plurality of mold inserts (8a) which are each designed to form a module (1). Device for carrying out the method, in particular for carrying out the first method step, according to one of claims 1 to 11,
characterized in that a filling device (17) is formed, which is movable at a defined speed over an upper opening (9) of a mold (8) to be filled, wherein the filling device (17) has an output means (18), and the movement the filling device (17) is synchronized with the dispensing means (18) such that the mold (8) is metered and filled with concrete (3) at least approximately uniformly. Device according to claim 12,
characterized in that the output means is designed as a conveyor belt (18). Device according to claim 13,
characterized in that the filling device (17) is movable from a trailing edge (9b) of the upper opening (9) of the mold (8) to a front edge (9a), during subsequent return movement of the filling device (17) from the front edge (17). 9a) to the trailing edge (9b) by a movement of the conveyor belt (18) or a vibration of the vibrating unit metered concrete (3) into the mold (8) is filled. Apparatus according to claim 13 or 14,
characterized in that the mold (8) has a plurality of mold inserts (8a) which are each designed to form a module (1).

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