RU2368742C1 - Method for manufacturing of wall-ceiling structure in reinforced concrete version - Google Patents

Abstract

FIELD: construction.

SUBSTANCE: invention is related to method for manufacturing of wall-ceiling structure in reinforced concrete version, when prefabricated non-withdrawable curb systems are used from wall curb system and ceiling curb system. Method for manufacturing of wall-ceiling structure in reinforced concrete version, in which non-withdrawable curb system is used from prefabricated wall curb system comprising two curb plates, which are installed at a distance from each other and are fixed to each other by means of fixtures, moreover, joining element between wall and ceiling is represented by mounting armature. For ceiling they use prefabricated non-withdrawable ceiling curb system, which is made without grid truss and comprises support plate, on which multiple separate longitudinal rods are placed parallel to each other, which, by means of multiple U-shaped brackets, which are installed on support plate with their angle shelves inverted to support plate and installed at the distance above support plate with their angle walls, are welded in angles between angle shelf and angle wall, and therefore separate longitudinal rods are fixed with the main plate at the distance from it so that separate longitudinal rods lie in lower area, especially in lower third of manufactured ceiling finished concrete ceiling. Ceiling system of curb and wall system of curb are fixed to each other so that separate longitudinal rods of ceiling curb system pass perpendicular to wall system of curb. Mounting armature on one side is inserted into wall curb system, and on the other side is fixed on separate longitudinal rods of ceiling curb system, so that mounting armature by means of separate longitudinal rods is fixed on support plate of ceiling curb system.

EFFECT: provides for manufacturing of wall-ceiling structure, especially, wall-ceiling joint.

5 cl, 2 dwg

Description

Technical field

The invention relates to a method for manufacturing a wall-and-ceiling structure in reinforced concrete design, using prefabricated, non-removable (left) formwork systems from a wall formwork system and a ceiling formwork system.

State of the art

In the manufacture of a traditional wall-and-ceiling structure made of reinforced concrete at the end (extreme) support, traditional wall formwork, as a rule, is first provided with the required static and structural mounting (connecting) reinforcement and poured with monolithic concrete. When the concrete reaches a certain strength, the construction of a ceiling formwork for a reinforced concrete ceiling can be started. This can lead to problems, especially in the area of the extreme support, which is defined as statically freely supported, but undergoes partial tension if, for example, a second wall is built over the extreme support. When the second wall is completed, then, according to the static theory, a tensile moment arises there, which must be removed by appropriate reinforcement. International or national regulations can be used to determine the required reinforcement.

For example, according to DIN 1045, 20.1.6.2. (2) it is prescribed that in the above case, a certain proportion of the calculated static reinforcement must be added to the end support. Such reinforcement on the end support protrudes into the ceiling area and interferes with further construction work, and also poses a risk of injury to construction workers working there, especially when the formwork is installed for reinforced concrete ceiling slabs and the necessary static and structural reinforcement. If the reinforcing bars protrude too far into the ceiling area, then it may be necessary to bend the reinforcing bars to set up the formwork table so that the formwork table can be installed. Such bending requires additional work steps and may have disadvantages.

However, with the help of auxiliary equipment available at the construction site, it is hardly possible to completely straighten a bent shaft in a cold state. The reinforcing bar, bent and again bent in the cold state, remains an S-shaped double curvature. Due to the forces at the inflection point caused by double curvature, tensile stress arises in the concrete, which can lead to cracks.

In addition, it may be necessary that the formwork be overlapped before the required reinforcement, and the formwork must be drilled at the intersection for reinforcing with the rods, or it should be an expensive butt joint, such as a socket joint, for which later it will be provided connectable bar reinforcement.

Further, in the practice of construction, a problem often arises when a wall-ceiling structure should be formed, for example, in the middle of the ceiling plate, and the load-bearing walls are not located one above the other for reasons due to use, but with a shift next to each other. In this case, the load-bearing wall ends on the floor, and thus the emerging loads are not transmitted from the load-bearing wall located below, the support, the beam, etc. to the appropriate foundation. This can be, for example, the case when for each floor a different application is provided (for example, a hotel: rooms are provided on the top floor, a restaurant is located on the lower floor, which has the maximum possible area that does not contain supports). The ceiling, which is formed in this place without supports, must bear the loads of the upper floors and the ceiling lying under the wall, as well as the additional own loads and transport loads acting on them, which can be statically and economically problematic, especially at large distances between the supports.

Another problem, known from the prior art, is that on the butt joints of conventional formwork systems when using conventional concrete, sweating of cement slurries of freshly laid concrete may occur. To avoid this, in conventional reusable formwork systems, a seal must be applied and appropriate release agents must be applied to the surface of the reuse formwork system so that the formwork can be separated from hardened concrete without damage to the concrete surface and the formwork surface. Damage to the concrete surface or sweating looks particularly unaesthetic in the case of facing concrete, and additional processing may be required.

In traditional formwork systems, additional problems may arise when still liquid concrete has to be compacted. In order to guarantee the filling of all cavities and the release of air when laying normal concrete into the formwork, internal vibrators are also used, as a rule. The use of an internal vibrator produces noise and vibration, which can adversely affect the maintenance personnel who hold the internal vibrator and immerse it in liquid concrete, as well as the immediate environment and the structure.

Along with the work load, due to improper handling of internal vibrators, significant damage to the formwork can occur. This is especially true for the outer surface of the formwork when direct contact with the internal vibrator occurs.

Also, direct contact of the internal vibrator with the reinforcement can lead to problems, such as, for example, in the section where the reinforcement is connected to the liquid concrete due to the vibration of the reinforcement due to the contact of the internal vibrator with the reinforcement, the gravel filler settles down from the reinforcement, and the proportion of cement the binder there is increasing. At the same time, there is no “support frame” formed by gravel filler, which must absorb pressure forces in hardened concrete that can occur during the transfer of forces between concrete and reinforcement.

EP 0611852 B1 proposes an interlocking formwork system for forming a wall. This system is applied on the principle of “non-removable” or “abandoned” or “permanent” formwork and is intended for the wall-ceiling construction method proposed by the invention.

EP0811731 B1 proposes a formwork system for forming a ceiling. This system is applied according to the principle of “non-removable formwork” and is intended for the wall-ceiling construction method proposed by the invention.

Disclosure of invention

An object of the present invention is to provide a method for manufacturing a wall-ceiling structure, especially in wall-ceiling joints.

According to the invention, two formwork systems are combined to construct a wall and a ceiling. The wall formwork system has two formwork panels which, by means of connecting devices, are kept apart from each other and fastened together. The ceiling formwork system, which is made without a trellis truss, contains a base plate, with the help of which many parallel longitudinal rods are fastened, which lie in the lower third of the constructed ceiling. Both formwork systems are connected to each other so that the longitudinal rods of the ceiling formwork system are perpendicular to the wall formwork system. As a transition from wall to ceiling in both formwork systems, the mounting (connecting) reinforcement is installed in such a way that it is connected to the individual longitudinal rods of the ceiling formwork system and, therefore, also directly to the base plate.

Thanks to the method of the present invention, it is possible to install a single formwork for the wall and ceiling in the area of the extreme (end) support of the ceiling and concrete them in one operation, while the reinforcement will not be bent, the formwork will not be drilled, and expensive butt joints will not be required. The method of the present invention combines in particular the advantages of the wall coupling formwork system according to EP 0611852 B1, which allows quickly producing large area wall panels, with the advantages of the ceiling system according to EP 0811731 B1, which, both in the case of manufacturing a ceiling before concreting, and in the case of a ceiling slabs in the finished state can take on a bearing function.

When creating an extreme support, when due to structural and / or static problems arising, partial stresses must be taken into account, using the method of the present invention, it is possible to simply and inexpensively respond to this partial stress. Thanks to the method of the present invention, it is possible to install the necessary structural and / or static reinforcement on the extreme support, which is subjected to partial stress, in the already installed wall formwork system and in the ceiling formwork system on the upper side of the ceiling formwork system. After the wall formwork system is installed, the ceiling formwork system can be installed immediately. At the same time, any reinforcing bars will not interfere, as is the case with concrete wall panels made in the usual way using removable formwork; there is also no need to wait for the concrete poured into the wall formwork to gain sufficient hardness so that after that it will be possible to begin the construction of the ceiling slab.

Particularly for the installation of the ceiling formwork system, the advantage is that the fittings necessary to relieve the moment arising due to partial stress during installation of the ceiling formwork system do not reach the ceiling area and therefore should not be bent, since this armature working on separation , is laid only when both the wall formwork system and the ceiling formwork system are installed. Tear-off fittings are fastened with suitable fasteners on one side of the wall formwork system and, on the other hand, on the existing formwork ceiling system consisting of separate rod fittings, with individual longitudinal rods of the ceiling formwork system entering the wall formwork system at the extreme support with the required mounting length. After the static and structural reinforcement, which is additionally required for peeling reinforcement, is embedded in the formwork systems, the wall formwork system and the ceiling formwork system can be filled with concrete in one working operation.

If you want to create a working seam between the upper edge of the concrete wall and the lower edge of the concrete ceiling on the extreme support with the wall formwork system, then on the extreme support use the same formwork slabs of the wall formwork, both the internal formwork plate facing the ceiling and the plate facing the ceiling formwork ends at the height of the base plate of the ceiling formwork system or the lower edge of the concrete ceiling. However, a cement binder may protrude on each working seam during concreting of a concrete ceiling, thereby deteriorating the aesthetic appearance.

To prevent the formation of a working seam between a concrete wall and a concrete ceiling at the lower edge of the ceiling, concreting of the wall and ceiling should be carried out without a temporary pause. For this, the outer formwork plate must be extended by a distance from the upper edge of the outer formwork plate to the finished upper edge of the concrete ceiling using additional formwork plates. However, the outer formwork plate of the wall formwork system for the external support can already be made in such a way that it will be higher than the inner formwork panel by the thickness of the concrete ceiling. This will prevent additional formwork at the construction site, which will facilitate concreting “in one go”, and the formation of a working seam between the wall and the lower edge of the ceiling will be prevented.

In the case of extreme support, due to partial tension, tensile stress arises on the upper side of the ceiling panel, which is perceived by tensile reinforcement, here referred to as tensile reinforcement. Using the method of the present invention, in the case of extreme supports subjected to partial stress, a better response to static and mechanical situations or to reaction forces (reference moment) is achieved.

Compared to a reinforced concrete ceiling plate, in which the extreme supports are designed and defined with free support, the deflection of the reinforced concrete ceiling plate made according to the method of the present invention is significantly improved due to the implementation of extreme supports, similar to corner frames. The required plate thickness is usually calculated from the limitation of the deflection of the plate. Due to the lesser deflection of the slab, the thickness of the slab can be made generally thinner and, therefore, cheaper compared to reinforced concrete ceiling slabs with extreme supports with free support with, otherwise, the same deflection.

Due to the fact that the tear-off reinforcement in the method according to the invention is laid only after the installation of the ceiling formwork system and the wall formwork system, it is not necessary to pay much attention to the installation of the armature, since, for example, it is not necessary to bend the armature up to install the formwork table for ceiling formwork system.

Thanks to the method of the present invention, the vertical adhesion between the reinforced concrete ceiling slab and the wall is improved, since the tear-off reinforcement connected to the individual longitudinal rods of the ceiling formwork system can be laid with a sufficient fastening length on the one hand in the wall formwork system and, on the other hand into the ceiling formwork system.

The method of the present invention can also be applied to the manufacture of a wall and bending wall truss for a suspended ceiling. Since the individual longitudinal rods of the ceiling formwork system, both in the manufacture of the ceiling and in the case of a ready-made reinforced concrete ceiling slab, take over the bearing functions and thereby are statically taken into account, the necessary suspension reinforcement can be fixed to hang the ceiling slab on a plane and bending to a wall truss at no cost with acceptable fasteners on the individual longitudinal rods of the ceiling formwork system. After the reinforced concrete ceiling panel is concreted and solidified, the wall adhesive formwork is connected to pendant fittings at no cost. The wall formwork system is equipped during its manufacture with the static and structural reinforcement required to form a panel that works in the plane and on the bend. This fixture has the form of mats and round steel (bars).

Self-compacting concrete is concrete particularly suitable for a method of manufacturing a wall-ceiling structure in reinforced concrete for concreting both of the above-described wall-ceiling formwork systems. In the case of self-compacting concrete, we are talking about normal concrete, which, when laid in the formwork due to gravity alone, fills all the cavities and independently, without the use of concrete compaction devices (for example, internal, i.e. submersible or deep vibrators), is deaerated. Thus, when laying self-compacting concrete, the supply of compaction energy for deaeration is not required. At the same time, the personnel necessary for compaction, as well as the devices necessary for compaction, are saved, the noise and vibration that occur when using concrete compaction devices are prevented.

The use of self-compacting concrete prevents errors such as damage to the formwork due to improper handling of internal vibrators and direct contact with the reinforcement. Due to the cohesive behavior of self-compacting concrete, as a rule, there is no problem sweating out fresh concrete. This reduces possible repairs. Other than in the case of vibrated concrete, the deaeration of which is improved by vibration of the vibrator, the deaeration of self-compacting concrete occurs due to the flow of concrete, without external energy.

Observations at construction sites have shown that with a 3-5 m flow length inside the mounting element, the concrete product has almost no sinks. The placement of self-compacting concrete in vertical mounting elements, such as walls and supports, and especially in the case of horizontal flat mounting elements, such as ceilings, is simplified by the self-leveling properties of the self-compacting concrete, i.e. self-compacting concrete has non-delaminating spreading until the level is completely leveled.

Brief explanation of the drawings

The invention is further illustrated by the example of preferred embodiments with reference to the drawings.

The drawings show the following.

Figure 1: a simplified diagram of the reinforcement in the context in the first example implementation of the method of forming a wall-ceiling structure of the present invention with a wall formwork system and ceiling formwork system.

Figure 2: a simplified diagram of the reinforcement in the context in the second embodiment of the method for the formation of a panel working in the plane and bending for a suspended ceiling with a wall formwork system and a ceiling formwork system.

The implementation of the invention

Figure 1 shows a diagram of the reinforcement in the context of wall-ceiling structures on the extreme support of a multi-storey building. The structure is manufactured using the method of the present invention, wherein prefabricated, non-removable formwork systems are used having a ceiling formwork system 120 and a wall formwork system 100.

The wall formwork system 100 of FIG. 1 can be implemented, for example, according to patent EP 0611852 B1 and contains two formwork plates, namely one facing from the ceiling, external formwork plate 101 and one facing the ceiling, internal formwork 103, which fasteners 102 are kept at a distance from each other and are connected to each other. The wall formwork system according to patent EP 0611852 B1 is particularly suitable for the manufacture of a wall-ceiling structure in reinforced concrete construction, since walls of a large area can be simply constructed using the wall formwork system. For the manufacture of wall formwork, slabs of the wall formwork system are joined by their butt edges (not shown) to each other. The abutting edges are parallel to each other on the long sides of the formwork plate, and the formwork plate on one abutting edge has protrusions for hanging (not shown), and on the other abutting edge has recesses for hanging (not shown) for connecting the formwork plates in the longitudinal direction of the wall formwork. The protrusions for hanging and the recesses for hanging are made in such a way that the protrusions of the second formwork plate attached to the installed first formwork plate are made so that the corresponding protrusions of the second formwork plate coincide with the recesses of the first formwork plate, which ensures quick installation of the wall surface of the large formwork wall. The formwork plates of the other wall are connected at a distance from each other in the transverse direction of the formwork wall using the fastening device 102.

The lattice-free truss ceiling formwork system 120 is preferably made according to patent EP 0811731 B and comprises a base plate 123, a plurality of separate longitudinal rods 121 parallel to each other and a plurality of brackets 122. The brackets 122 are arranged in several parallel rows distributed over the base plate 123 and are preferably made U-shaped with corner shelves directed to the base plate 123, and with corner walls extending parallel to the base plate 123 at a certain distance from it. The corner shelves can be provided at their free ends with 90 ° flange plates bent away from them, with which the brackets 122 are fastened, for example, with bolts, to the base plate 123. The individual longitudinal rods 121 are welded in the corners between the shelves and the walls of the brackets 122, which have such a height that the individual longitudinal rods 121 after laying the concrete lie in the lower region of the finished concrete ceiling 171, especially in the lower third of the thickness of the concrete ceiling. Additional reinforcing bars in the concrete ceiling 171 are not provided.

Therefore, in the hardened state of the concrete ceiling, the individual longitudinal rods 121 are under tensile stress, and thereby can absorb tensile stress. During construction, on the contrary, individual longitudinal rods 121 can be taken into account in static calculations before and during concrete pouring, which reduces the number of necessary supporting devices and the required installation and dismantling time, since separate longitudinal rods 121 before pouring concrete and before hardening the concrete layer transfers compressive forces, while the base plate 123 transmits tensile forces.

First, the wall formwork clutch system 100 is installed and fixed with a suitable (not shown) temporarily installed support device against the pressure that occurs when pouring liquid concrete, and the required structural and static reinforcement (not shown) of the concrete wall 172 can be laid together with the formwork walls. Then, differently from the methods of the prior art, the ceiling formwork system 120 is mounted on the wall formwork system 100, the individual longitudinal rods 121 of the ceiling formwork system 120 extending perpendicular to the wall formwork system 100, and are fastened and sealed using suitable means the inner formwork wall 103 of the wall formwork system in such a way that until the wall formwork system 100 is filled with concrete, concrete or cement binder cannot exit. The individual longitudinal rods of the ceiling formwork system 120 can be sized so that at the extreme support they enter the wall formwork system with the required fastening length, that is, at least protrude beyond the reference support line. The required fastening length of individual longitudinal rods can be prepared both with direct and indirect support on the extreme support with a ceiling formwork system.

In the case of the embodiment shown in FIG. 1, the inner formwork plate 103 of the wall formwork system 100 adjacent to the ceiling 171 is lower by the thickness of the finished ceiling 171 than the formwork plate 101 facing away from the ceiling, and the base plate 123 of the formwork ceiling system 120 is flush with the inner plate 103 formwork and facing the wall.

If both formwork systems 100, 120 are fixed with the appropriate supporting devices against concrete pressure and against loads arising in another way, and the reinforcement additionally provided in the ceiling 171 is laid and fixed, then one mounting (connecting) reinforcement 150 per linear meter is used on the extreme support, which is connected by appropriate anchor means on the one hand to the wall formwork system 100, and on the other hand to the ceiling formwork system 120.

Mounting (connecting) reinforcement 150 on the extreme support has angular reinforcement 151 that works on separation, and especially also distribution reinforcement 155, for example, in the form of round steel (bar), at the top of the angle of reinforcement 151. The reinforcement 151 working on separation is installed with the first shelf 152 between the slabs 101, 103 of the formwork of the wall formwork system 100, with the distribution fittings 155 also located in the wall formwork system, and the other, second shelf 153 lies in the upper region of the manufactured ceiling 171. The tear-off armature 151 is suspended its second shelf 153 protruding to the ceiling 171 by means of a structural fastener 154 under the individual longitudinal rods 121 and / or their fastening bracket 120, which positively affects, among other things, the required fastening length of the reinforcement 151 in the concrete ceiling 171. The fastening length can thereby be shortened which means less steel.

After the tear-off reinforcement 151 is mounted on top, the wall formwork system 100 together with the ceiling formwork system can be filled with concrete. Any suitable concrete may be used as concrete, and in this method, self-compacting concrete is particularly suitable. Due to the use of self-compacting concrete, it is not necessary to compact and deaerate liquid concrete with the help of internal vibrators, which in turn saves additional work steps. If one additional floor is provided, as shown in Fig. 1, then in a similar manner, as described above, the ceiling-wall formwork system is built on the working seam 190 on the extreme support and is accordingly poured with concrete.

Referring to FIG. 2, a simplified diagram of a wall formwork system 100 in the form of a plane and curved wall frame 272 for a suspended ceiling, which is manufactured according to the method of the present invention, wherein the prefabricated non-removable formwork systems belong to the formwork ceiling system 120 and shown in section, is shown. wall system 100 formwork.

In this case, using the ceiling formwork system 120, a concrete ceiling 171 is first produced, which, for example, can be supported by brickwork or a concrete wall.

Before concreting the concrete ceiling 171, the ceiling formwork system 120 is provided with the necessary structural and / or static reinforcement. To form the panel or wall that is required to work here in the plane and bend before concreting the concrete ceiling 171, statically or structurally defined mounting (connecting) reinforcement 150 is laid in the ceiling formwork system 120, which has suspended reinforcement 252 and its anchor elements 154, which are laid on the running meter in the ceiling formwork system 120 for engagement with the wall formwork system 100. Also here, the anchor elements 154 are installed under the individual longitudinal rods 121 of the ceiling formwork system 120 and connected to it. After completion of the reinforcement work, the concrete ceiling 201 is poured with concrete. After the concrete has gained sufficient strength, the wall formwork system 100, which is equipped at the factory with the necessary reinforcing mats 210 and reinforcing rods 211 to form a wall 272 working in the plane and bend, is mounted on the working seam 190 and fixed with suitable support devices not shown . The ledge of the pendant reinforcement 252 emerging from the concrete ceiling 171 is connected by means of fasteners to reinforcing mats 210 and / or reinforcing bars 211. Then, the wall formwork system 100 can be filled with concrete.

In the case of the wall formwork system 100 and the formwork ceiling system 120 shown in FIGS. 1 and 2 according to the method of the present invention, self-compacting concrete is particularly suitable as concrete because of its good qualities, such as non-delaminating spreading until the level is completely equalized, almost complete deaeration without additional compaction work and compaction without defective areas. Due to the fact that the active compaction disappears, the noise level at the construction site is generally reduced, the laying performance is increased, and fewer personnel are required to lay self-compacting concrete, since there is no need to operate an internal vibrator due to self-deaeration of self-compacting concrete, and due to self-leveling of self-compacting concrete, especially in the case of horizontal ceilings, there is no need to level the concrete ceiling.

Claims (6)

1. A method of manufacturing a wall-and-ceiling structure in reinforced concrete design, in which an indelible formwork system is used from a prefabricated wall formwork system (100) containing two formwork plates (101; 103), which are located at a distance from each other by means of fastening devices (102) from each other and attached to each other, and as a connecting element between the wall and the ceiling, mounting fittings (150) are used, characterized in that the ceiling is made of prefabricated non-removable The ceiling formwork system (120), which is made without a grating truss and contains a base plate (123), on which are placed a plurality of separate longitudinal rods (121) placed parallel to each other, which, by means of a plurality of U-shaped staples (122), which with their the corner shelves facing the base plate are mounted on the base plate and with their corner walls are located at a distance above the base plate, welded in the corners between the corner shelf and the corner wall, and thus the individual longitudinal bars heat with the main plate (123) at a distance from it so that the individual longitudinal rods lie in the lower region, in particular in the lower third of the thickness of the finished concrete layer of the manufactured ceiling (171),
moreover, the ceiling formwork system (120) and the wall formwork system (100) are attached to each other so that the individual longitudinal rods (121) of the ceiling formwork system (120) extend perpendicular to the wall formwork system (100), and
moreover, the mounting reinforcement (150) is inserted on one side of the formwork into the wall system (100), and on the other hand, it is mounted on separate longitudinal rods (121) of the ceiling formwork system (120), so that the mounting fittings (150) are mounted on separate longitudinal rods base plate of the ceiling formwork system. 2. The method according to claim 1, in which to connect the ceiling (171) with the wall (172), which serves as an extreme support, the ceiling formwork system after installing the wall formwork system (120) is placed on it, after which from the upper side of the ceiling system ( 120) the formwork as mounting fittings (150) install the tear-off corner fittings (151) with one of its shelves (152) into the wall system (100) of the formwork, and the other with its shelf (153) is attached to separate longitudinal rods (121), after bringing the ceiling (171) and the wall (172) with concrete in one operation. 3. The method according to claim 2, in which the wall formwork system (100) is preliminarily made in such a way that the inner formwork plate (103) facing the ceiling is lower than the external formwork plate facing the ceiling (101), the ceiling formwork system being installed flush on the inner formwork plate (103) of the wall formwork system (100). 4. The method according to claim 1, in which for hanging the ceiling (171) under the wall (272), made as a wall truss working in the plane and bending, the ceiling formwork system (120) is propped up, and the mounting fixture (150) as a suspension reinforcing bars (252) are attached to the individual longitudinal rods (121) of the ceiling formwork system (120), so that the portion of the mounting fittings protrudes upward, and the ceiling formwork system is poured with concrete, thereby constructing the ceiling, after which the wall formwork system (100) is placed on the constructed ceiling (171) and thus to a suspension reinforcement (252) which goes beyond the upper edge of the ceiling, it juts inwardly between the shuttering boards (101) a wall system (100) and connected to the shuttering wall formwork system. 5. The method according to one of claims 1 to 4, in which self-compacting concrete is used as concrete.
Priority on points: July 28, 2005 according to claims 1-5.

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