EP2687346A1 - Procédé et appareil de frabrication - Google Patents
Procédé et appareil de frabrication Download PDFInfo
- Publication number
- EP2687346A1 EP2687346A1 EP12177352.7A EP12177352A EP2687346A1 EP 2687346 A1 EP2687346 A1 EP 2687346A1 EP 12177352 A EP12177352 A EP 12177352A EP 2687346 A1 EP2687346 A1 EP 2687346A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- fibre cement
- sheets
- formwork
- sheet
- hardening
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/30—Producing shaped prefabricated articles from the material by applying the material on to a core or other moulding surface to form a layer thereon
- B28B1/38—Producing shaped prefabricated articles from the material by applying the material on to a core or other moulding surface to form a layer thereon by dipping
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/52—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B7/00—Moulds; Cores; Mandrels
- B28B7/40—Moulds; Cores; Mandrels characterised by means for modifying the properties of the moulding material
- B28B7/46—Moulds; Cores; Mandrels characterised by means for modifying the properties of the moulding material for humidifying or dehumidifying
Definitions
- This invention belongs to the field of manufacturing fibre cement sheets, particularly the field of manufacturing lightweight façade decorations and roof sheets with various shapes and imitation patterns.
- Fibre cement sheet is a widely used building material. It is mainly utilised for roof covering (for example as wave-profiled sheets and as shingles) and façade covering (for example as printed imitation of wood, stone and bricks); fire-resistant fibre cement sheets are also made.
- the well-know solutions have a sheet thickness of 5 to 6 mm for roof covering and mainly 6 to 12 mm for façade covering (up to 20 mm as imitation of bricks or natural stone).
- Fibre cement is also used for manufacturing garden furniture. Fibre cement sheets have proven to be a very durable building material.
- the well-known process of manufacturing fibre cement sheets consists of the stages of preparing the raw materials, forming the sheets, drying the sheets and if necessary then finishing the sheets.
- the raw material preparation stage utilises mainly cellulose instead of asbestos.
- the exact constitution of the mixture depends largely on the drying method.
- the cellulose is mixed with durable synthetic fibres, e.g. PVA (polyvinyl alcohol) or PAN (polyacrylonitrile), depending on the required physical properties of the finished product.
- PVA polyvinyl alcohol
- PAN polyacrylonitrile
- the most commonly used binder material for manufacturing fibre cement sheets is Portland cement, supplemented by finely ground limestone (dust) or quartz sand. Lower-weight filler materials are used in some cases.
- 50% of the cement is substituted by finely ground quartz sand (with high silicone dioxide - SiO 2 - content).
- quartz sand content may be up to 25%.
- Ordinary quartz sand is finely ground in a special wet mill with rubber lining, resulting in sand slurry.
- Sand slurry is pumped into a slurry pool where mixers retain the slurry in a state of suspension.
- a computer calculates the water content already present in the slurry and configures the dosing equipment for automatic addition of the necessary additional water.
- the production water is utilised repeatedly in the technological process.
- the cellulose slurry is pumped onto scales and dosed as a primary component.
- the mixing order is as follows: the slurry is directed into the main mixer; then cement, additives and production water are added (the specific details of the procedure depend on the formula of the mixture and the quality of the raw materials); the mixing time is configured for an optimum mixture quality; recuperators add clean production water.
- the freshly made slurry is stored in a pool where it remains until it has to be added to the homogeniser for further use in the sheet forming machine.
- the homogeniser carefully mixes together the fresh slurry coming from the slurry pool, the reject material redirected from production, and the waste materials. Production water is added until attaining the required density of the mixture (the automation calculates the ratio of volume and mass of the mixture).
- Freshly made sheets are cut to prescribed dimensions. Different cutting systems are required for manufacturing standard straight sheets, lining sheets, shingles or wave-profiled roofing sheets. Cutting of fresh sheets may be the final cutting or it may be preliminary cutting followed by hardening and second, i.e. final cutting.
- Profiled surface of the sheets is formed directly by a forming roller (without additional pressing) or with a press roller. Wave-profiled sheets are pressed with a single press. Follow-up pressing increases the weather resistance of the sheets.
- the air-drying fibre cement sheets are stacked onto trolleys for preliminary hardening as a mixed stack, i.e. straight of wave-profiled steel sheets are placed between fibre cement sheets.
- Autoclave-hardening sheets are stacked without intermediate sheets. After the sheets have hardened somewhat (the duration of such preliminary hardening depends on the cement being used), the hydratation of cement makes the sheets sufficiently hard and the sheets are sent to full hardening in air (air-drying sheets) or in an autoclave (autoclave-hardening sheets).
- the air-drying sheets are placed on wooden bases and left in air for 2-4 weeks of follow-up hardening (at room temperature).
- the autoclaving process begins with steaming and gradual increasing of pressure until 10-12 bar at the temperature of 180-190°C. Once attained, the pressure and the temperature are kept stable for a few hours, until calcium silicate hydrate forms and the sheets harden. In the end of the autoclaving cycle, the pressure decreases slowly to the atmospheric level.
- Fully hardened sheets are processed in machines which apply surface covering or paint cover to them or grind their surfaces and edges.
- the methods known from the current level of technology allow manufacturing large quantities of high-quality fibre cement sheets (the production capacity of a production line is approximately 2 to 20 t/h).
- the thickness of the produced sheets is approximately 4 to 20 mm.
- the main existing forming technologies Hatschek, Flow-on, etc.
- Fresh (unhardened) straight sheets can be formed into profiles, but in a limited way.
- Sharper profiles can have up to 2 mm of depth. As a rule, only one side of the sheet can be profiled. Wave-profiles must have a gentle line. Pressing in sharper profiles would bend the fibre ends loose at the bending lines or would cause tears in the sheet. This in turn would deteriorate the looks and the strength of the sheets.
- Sheets manufactured with the extruder technology can have a deeper pattern on one side (approx. 10 mm), but only with higher sheet thickness (approximately 20 mm).
- the technologies currently used in the world do not allow manufacturing fibre cement sheets with complex profiles.
- Façades are divided into ventilated and non-ventilated façades. Ventilated façades have an air gap between the thermal insulation and the façade covering; non-ventilated façades have no air gap. In case of non-ventilated façades it is recommended that the façade covering be made of a breathing material. This allows the effect where moisture entering the walls can dry off to outside. In ventilated façades the moisture can escape via the air gap and thus the breathing properties of the external cover material are not important.
- roof tiles There is a wide variety of different roof covering materials used in the world. One of the most common among those is roof tiles. They are good-looking, durable, don't make loud noise in rain and they are breathing. On the other hand, roof tiles are usually heavy (requiring large transport expenses and a carrier structure with high load-bearing capacity), and the tiles are small and thus require lots of time to install.
- the purpose of this solution is to offer a method and equipment for manufacturing fibre cement sheets with any level of profile complexity, and to offer a profiled fibre cement sheet which could be used as a façade covering for non-ventilated façades.
- the sheet made with the method detailed in this invention is a shell with a uniform thickness, whereas in large-volume production the thickness would be in the range of 1.5 to 5 mm and the profile depth would be up to 100 mm having any level of profile sharpness. Production volumes would decrease when manufacturing the sheets with thickness over 5 mm.
- the fibre cement sheet manufactured according to this method has less thickness and less weight when compared to fibre cement sheets manufactured with the currently known technologies and having the same physical properties.
- the low weight and the unlimited profile options allow the fibre cement sheet manufactured with this method to be utilised in various areas of constructions where it has been impossible until now. For example, it is possible to manufacture sheets with various patterns and profiles, to be glued onto thermal insulation. The method also allows manufacturing sheets with all kinds of roof tile imitations or imitations of other stone materials, which is not possible with the currently known technologies.
- This method allows manufacturing lightweight fibre cement sheets with various shapes (for example as façade decoration), to be glued directly to thermal insulation with glue mortar. Such sheets don't require any screws or other additional fixtures for installing.
- the various patterns of the fibre cement façade decorations can be e.g. imitation of bricks or natural stone, etc.
- the edges of the façade decoration sheets have overhang. The edge of the upper sheet is always on the edge of the lower sheet. Thus any water will always flow from the upper sheet to the lower sheet and this excludes any water seeping behind the decoration.
- the joints of sheets are not filled. This allows the sheets to have some thermal play without encountering mechanical stresses. Finishing materials for façade decoration sheets must be silicate paint and fine sand, as these are also breathing materials.
- the fibre cement façade decoration made with this method is breathing, has lower cost price and is easier and faster to install.
- the roof sheet comprises a monolithic fibre cement sheet with a thickness of approximately 5 mm, looking like approximately 8 assembled roof tiles. Any kind of roof tiles can be imitated.
- the equipment for manufacturing profiled fibre cement sheet as detailed in this invention includes a device for forming and shaping the fibre cement sheet, a conveyor for preliminary hardening of the fibre cement sheet, a flow-through shelf for follow-up hardening of the fibre cement sheet, and a template painting system for finishing the fibre cement sheet.
- the method of manufacturing profiled fibre cement sheets as detailed in this invention includes the stages of preparing raw materials, forming the fibre cement sheets, preliminary hardening of the sheets, follow-up hardening of the sheets and finishing the sheets.
- a mixture is prepared which has a 2 to 40 (preferably 10 to 14) times less volume than the mixture prepared in the currently known process of manufacturing air-drying fibre cement sheets.
- Cellulose is supplied to the factory as packages. After soaking in water, cellulose is separated into fibres and then directed into the cellulose slurry pool. Bleached and unbleached cellulose can be used. Cellulose is used for strengthening the fibre cement sheets, but it also acts as a technological fibre, facilitating the process of producing synthetic fibres. In the course of fibrillating, cellulose is separated into fibres and thus attains maximum strength.
- Cellulose is mixed with durable synthetic fibres like PVA (polyvinyl alcohol) or PAN (polyacrylonitrile), depending on the required physical properties of the finished product.
- the synthetic fibres provide the end product with strength and durability.
- the cellulose slurry is pumped onto scales and dosed as a primary component.
- the binder material of the fibre cement sheets manufactured with this method is Portland cement and the main additive is finely ground limestone dust or finely ground quartz sand, supplied in tanker trucks or railcars and stored in outdoors silos.
- the silos should have the storage capacity satisfying the raw material need for 3-12 work days (this volume depends on the supply certainty of the components).
- the daily needed volume is directed into day silos located inside the production building where the materials attain room temperature. Cement and additives are dosed onto scales by separate screw dosers.
- the overall volume of water has an important role in the composition of the mixture.
- the system automatically regulates the water content in the mixture.
- a computer calculates the water content already present in the slurry and configures the dosing equipment for automatic addition of the necessary additional water.
- the production water is utilised repeatedly in the technological process.
- the mixing order is as follows:
- the freshly made slurry is stored in a pool where it remains until it has to be added to the homogeniser.
- the homogeniser carefully mixes together the fresh slurry coming from the slurry pool, the reject material redirected from production, the waste materials and the production water, until attaining the required density of the mixture. From the homogeniser, the slurry is directed into the sheet forming machine.
- the mixture composition for the fibre cement sheet manufactured with this method is similar to the mixture composition used for manufacturing the sheets with the Hatschek technology known from the current level of technology.
- PVA polyvinyl alcohol
- PAN polyacrylonitrile
- composition described above is one of the preferable variants.
- the exact composition of the mixture is determined according to the required parameters and intended purpose of the sheets.
- colouring agents can be added to the slurry; this results in the entire sheet being of single tone throughout its thickness.
- the equipment for manufacturing profiled fibre cement sheet as detailed in this invention includes a device for forming and shaping the fibre cement sheet (as shown in the following drawings: Figure 2 , Figure 3a and Figure 3b and Figures 4-1 to 4-7 ), a conveyor for preliminary hardening of the fibre cement sheet (as shown in the following drawing: Figure 5 ), a flow-through shelf for follow-up hardening of the fibre cement sheet (as shown in the following drawing: Figure 6 ) and a template painting system for finishing the fibre cement sheet (as shown in the following drawing: Figure 7 ).
- the equipment to be used in the stage of forming the fibre cement sheet includes a slurry bath 1 into which the slurry 2 is added, a mixer 3 added to the slurry bath 1, oil sprayers 11 and a moving formwork which comprises a shell 4, a vacuum chamber 5 located inside the shell 4, a covering sieve 6 which covers the outside of the work surface of the formwork (the covering sieve's mesh openings should preferably be sized approximately 0.5 mm), water removal channels 7 between the covering sieve 6 and the vacuum chamber 5, a vacuum pipe 8, fastening eyes 9 of the formwork, and a counterpart 10 of the formwork, whereas the formwork may be positioned in two ways (as shown in the following drawings: Figure 3a and Figure 3b ).
- the work surface of the formwork is directed down.
- the work surface of the formwork is directed up.
- the work surface of the formwork is directed up.
- the formwork can move up-down on a straight line or in a circle.
- the formwork can move up-down on a straight line only.
- step 7 the sheets are directed into cold pressing.
- Cold pressing is a secondary pressing of the sheet with a force of 80-220 kg/cm 2 .
- the remaining surplus water is removed from the sheet, the sheet attains a higher density (its thickness is reduced by up to 30% due to pressing), and as a result the sheet becomes more resistant to weather.
- the side of the sheet that was against the covering sieve 6 displays the profile of the covering sieve 6; this is due to the fact that the surface of the initial formwork is covered by the covering sieve 6.
- the initial pressing doesn't allow finer patterns (less than 5 mm) to be pressed into the sheet.
- a fine pattern startsing from 1 mm is pressed into the sheet without changing the main shape of the sheet.
- Cold pressing can be performed as a single pressing (1 sheet at a time) or as a package pressing (in a mixed stack of die-sheet-die-sheet etc.). Unlike with well-known methods, the cold pressing dies are made of highly abrasive-resistant polyurethane.
- Dies made of the aforementioned material don't require oiling during the process and have a very long service life. Unlike with well-known methods, the dies utilised in package pressing have a two-sided profile. Cold pressing gives the sheet its final surface profile.
- the preliminary hardening stage of the method detailed in this invention takes place at room temperature and lasts for at least 8 hours. Due to the chemical process taking place inside the fibre cement sheet, its temperature may rise up to the level of 80°C.
- FIG. 5 shows the conveyor system to be used in the equipment detailed in this invention, in the stage of preliminary hardening of the fibre cement sheet; the drawing shows the movement of the fibre cement sheets.
- the conveyor system should preferably have multiple storeys and comprises elevators 13, trolleys 14, trolley pockets 15 attached to lifting cables 16 of the elevator 13, a pusher 17 and the guiding rails 18 of the trolleys.
- the elevator 13 directs the non-hardened fibre cement sheets 12 onto the trolleys 14 moving on the guiding rails 18 of the trolleys on the storeys of the conveyor system; at the end of the process, another elevator 13 directs the preliminary-hardened fibre cement sheets 19 off from the trolleys.
- the fibre cement sheets attain sufficient strength to have them stacked on a pallet.
- the fibre cement sheets stacked onto a wooden pallet are directed into follow-up hardening.
- the equipment detailed in this invention utilises a flow-through shelf shown in Figure 6 .
- the follow-up hardening stage of this method takes place at the preferable temperature of 10-20°C and lasts for 2 to 4 weeks.
- the fibre cement sheets are stacked onto pallets 21 which are stored in the flow-through shelf 22 using a loader 20.
- a ramp 23 runs through various subsequent storage places.
- the incline of the ramps 23 of the flow-through shelf 22 is approximately 4%.
- the pallets 21 have rollers and move under gravity to the right places by themselves.
- the rollers have special brakes preventing any acceleration when moving on the ramp and thus preventing damages to the goods.
- the flow-through shelf 22 should preferably operate according to the FIFO principle; the fibre cement sheets are well protected, the risk of damaging them is minimised and the efficiency of utilising the warehouse space is high.
- the number of subsequent storage places on a ramp running through the flow-through shelf 22 should preferably be equal to the number of days that a sheet spends in follow-up hardening. In that case, the same number of pallets 21 are added to each ramp in each day and taken off each ramp at the other side of the flow-through shelf in each day. In that case, the pallets 21 being taken off have passed through the entire ramp in the number of days prescribed for follow-up hardening.
- the fibre cement sheets manufactured according to this method are ready to be used after the follow-up hardening and need no follow-up finishing.
- the fibre cement sheet finishing stage of the method detailed in this invention is performed additionally after the follow-up hardening, depending on the requirements and the design of the fibre cement sheet being manufactured.
- the fibre cement sheets stacked onto pallets 21 must be unstacked again and directed to the finishing line. Finishing can mean painting with a single or multiple paint layers (applied by a roll or a spray), covering with various crushed materials and/or waxing the back side of the sheet. Template painting is used for finishing the façade decoration sheets described above.
- FIG. 7 shows a schematic of the template painting system of the equipment detailed in this invention.
- the fibre cement sheets 24 to be painted move in a position where their side to be painted is directed down.
- the fibre cement sheets 24 to be painted are held hanging from the conveyor 28 with vacuum heads 26 of the hangers 27.
- a fibre cement sheet 24 to be painted moving on the conveyor 28, reaches a template 25, the fibre cement sheet 24 starts pushing the template 25 along; this ensures synchronous movement and precise positioning of the template 25 on the fibre cement sheet 24 to be painted.
- the template 25 has openings above the areas of the fibre cement sheet 24 which are to be painted. When the fibre cement sheet 24 and the template 25 reach above the painting box 29, the sprayer 30 activates.
- Templates 25 have wheels 31 for moving along guide rails 32; templates 25 move under gravity towards under the painting box 29 via the guide rails 32 and are then lifted to above the painting box 29 again by way of an escalator (not shown in the drawing), whereas templates 25 are not connected to each other.
- the templates 25 can be various, i.e. different areas of different fibre cement sheets can be painted. This method avoids repetition of the pattern. This is very important when imitating natural materials. Façade decoration sheets can be followed up by spraying fine sand onto them, which sticks to the fresh paint layer.
- the method detailed in this invention allows manufacturing fibre cement sheets with lower thickness (dimension a in Figure 9 ) of 1.5 to 5 mm and a profile depth (dimension b in Figure 9 ) of up to 120 mm.
- the profiled fibre cement sheet detailed in this invention has a thickness range of 1.5 to 3 mm and a profile depth range of 10 to 120 mm.
- Figure 10 and Figure 11 show implementation examples of profiled fibre cement sheets manufactured according to the method detailed in this invention.
- the fibre cement sheets manufactured according to this method can have imitation patterns 33 (e.g. slates, bricks, roof tiles, etc.), imitation edges 34, imitation vertical joints 35, imitation horizontal joints 36.
- the implementation example of a fibre cement sheet shown in Figure 10 also has a fastening opening 37, grooves 38 hindering lateral movement of water, and grooves 39 ensuring proper positioning of fibre cement sheets to each other.
- the implementation example of a fibre cement sheet shown in Figure 11 also has an overhang 40.
- the surface structure of the profiled fibre cement sheet manufactured according to this method allows imitating other façade materials which form structured surfaces.
- the fibre cement sheets detailed in this invention allow making watertight smooth surfaces. Water removal is ensured via overhangs of edges of the fibre cement sheets, where each upper row of the sheets is placed onto the previous lower row of the sheets. In this case, the overhung edges are located lower, thus the covered surface can be smooth if wished.
- Such shape and placement of the fibre cement sheets precludes the wall structure becoming wet, and there will be no visible rests and removal works of glue or installation mixture used for attaching the fibre cement sheets to the underlying surface.
- the fibre cement sheet detailed in this invention allows easier placement of the sheets on the underlying surface when compared to the currently known solutions, because the precise pressing and cutting of the fibre cement sheets in the production process and its profile pattern make it unnecessary to perform additional measurements in the course of the installation process. Thanks to the advantages over the currently known solutions, this fibre cement sheet provides extended architectural opportunities for outdoors and indoors use without the need for additional finishing or covering.
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- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- Mechanical Engineering (AREA)
- Curing Cements, Concrete, And Artificial Stone (AREA)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP12177352.7A EP2687346A1 (fr) | 2012-07-20 | 2012-07-20 | Procédé et appareil de frabrication |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP12177352.7A EP2687346A1 (fr) | 2012-07-20 | 2012-07-20 | Procédé et appareil de frabrication |
Publications (1)
Publication Number | Publication Date |
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EP2687346A1 true EP2687346A1 (fr) | 2014-01-22 |
Family
ID=46704457
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP12177352.7A Withdrawn EP2687346A1 (fr) | 2012-07-20 | 2012-07-20 | Procédé et appareil de frabrication |
Country Status (1)
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EP (1) | EP2687346A1 (fr) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP3072863A1 (fr) * | 2015-03-23 | 2016-09-28 | FibreCem Holding AG | Procede de fabrication d'un element composite fibre/ciment |
WO2018229787A1 (fr) * | 2017-06-16 | 2018-12-20 | Everest Industries Limited | Procédé et système de production d'une feuille de couverture en couleur et feuille de couverture associée |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
FR2201647A5 (fr) * | 1972-10-04 | 1974-04-26 | Everitube | |
JPS54106532A (en) * | 1978-02-08 | 1979-08-21 | Sekisui Chemical Co Ltd | Production of inorganic molding articles |
JP2003154510A (ja) * | 2001-11-21 | 2003-05-27 | Matsushita Electric Works Ltd | 無機質板の製造方法 |
-
2012
- 2012-07-20 EP EP12177352.7A patent/EP2687346A1/fr not_active Withdrawn
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
FR2201647A5 (fr) * | 1972-10-04 | 1974-04-26 | Everitube | |
JPS54106532A (en) * | 1978-02-08 | 1979-08-21 | Sekisui Chemical Co Ltd | Production of inorganic molding articles |
JP2003154510A (ja) * | 2001-11-21 | 2003-05-27 | Matsushita Electric Works Ltd | 無機質板の製造方法 |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP3072863A1 (fr) * | 2015-03-23 | 2016-09-28 | FibreCem Holding AG | Procede de fabrication d'un element composite fibre/ciment |
WO2018229787A1 (fr) * | 2017-06-16 | 2018-12-20 | Everest Industries Limited | Procédé et système de production d'une feuille de couverture en couleur et feuille de couverture associée |
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