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Concrete Repair Method | Waterproofing

Contractor

Repair Strategy

• Material selection
• Method selection
• Support Design
• Safety Precaution
• Costs
• Logistics

Process

• Re-bars
– Undercutting
– Cleaning
– Repair
– Protect
• Concrete
– Surface preparation
– Bonding
– Apply new material

Performance Requirements of Concrete Repair

• Protection of Rebars
• Aesthetics
• Integrity and Compatibility (with substrate)
• Carry loads
• Waterproofing

Repair Systems Selection Criteria

• Stability of element
• Cost
• Disturbance to users
• Existing concrete condition
• Exposure condition
• Compatibility of repair material to substrate

Concrete Repair Methods

Buildings Department (1998) lists the following common repair techniques for concrete:

– Patch Repair
– Recasting/Partial Recasting
– Sprayed Concrete
– Micro-concrete
– Pre-packed concrete
– Non-shrinkage grout
– Sealing system

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– Protective Coating

Traditional Repair Methods

– Patch Repair

• Cementitious mortars
• Resin-based mortars

– Recasting/Partial Recasting

– Sprayed Concrete

• Dry process spray

• Wet process spray

Preparation Before Work

– Preparation of concrete surface

– Cleaning of reinforcement
– Coating reinforcement
– Bond Coat

Preparation

• Marking out, Hack back to 10-20mm behind re-bars, ensure concrete cover
• Saw cut the edge, Brush/grind the re-bar
• Prime coat for re-bar, bond coat for substrate
• Batching of repair mortar and apply.
• Dowel bars:
• Holes drilled with rotary-percussive drills to provide keys
• Air blown by pneumatic device
• Required length of insertion
• Give it a 1/2 turn and then turn back to original position
• Give 2 hrs initial set off time

Cleaning of reinforcement

• For cleaning of reinforcement rust, high pressure water-abrasive blasting should be the
best ways of ensuring a chloride-free surface for the reinforcement. Probably, it is the only
way of removing chlorides from the pits in rusting reinforcement.
• If the damage is caused by carbonation, it is less critical to remove rust from the
reinforcement. Coating with a layer of firmly adhering cement paste will be sufficient to
prevent further deterioration. Other material for coating can be used if the repair is not in
a cementitious one.

1. Patch Repair

• It is most suitable for small-volume repairs as to restore concrete’s durability. The

damaged concrete should be removed and patched up with appropriate repair mortars.
• In general, there are two common repair mortars used for repairing works:
– Cementitious mortars
– Resin-based mortars
• i. Cementitious mortars:
• Cementitious mortars is one type of repair mortars for patch repair on small-volume
repairs. It is used to restore durability of the structure. The damaged concrete is removed
and these areas will be patched up with appropriate repair mortars.

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1. Patch Repair (Cont’d)

• Mailvaganam and Taylor (1994) prefers resin based mortars. It is because the resin based
mortars have an elastic modulus of about one-tenth of concrete.
• The coefficient of thermal expansion is five times more than that of concrete.
• It has the strongest compressive strength than the other type of cementitious based
mortars.
• Recently, polymer is added into the mortar in order to increase their strength.
• However, there are some limitations in polymer repair materials e.g. it may cause
delamination or blistering when applied on the damped areas; and
• It is not recommended to be applied in areas where fire resistance is required. It has poor
fire resisting property and it has thermal incompatibility with substrate concrete.

Types of Mortar

Types of
Suitability Reference
cementitious mortars
For area where superior resistance is
Renderoc GP;
Medium-weight required to chlorides and carbon dioxide.
Renderoc HB40 (with
cementitious mortar For general purpose concrete
higher performance)
reinstatement.
Fibre-reinforced, For repair of spalling, honeycombing, stair
Lanko 731
nonshrinkage mortar nosing, ramp etc.
Silica fume-modified
Emaco S66 Emaco
Silica fume-modified
For repair load-bearing concrete S88C; Emaco S88C
repair mortar
with MCI

Types of Mortar (Cont’d)

Polymer modified
Polymer modified repair For locations where required high Barra 80; Barrafill;
mortar suitable for different compressive strength, and reinstatement Renderoc S; Ronafix
degree of exposure of concrete. Mix A; Ronafix Mix D
Polymer modified repair Restore concrete and inhibit
mortars, feature shrinkage further deterioration before significant Emaco R740
compensating properties structural damage occurs.
For high build, vertical and overhead Barra Mortar HL;
Polymer modified repair
repairs (rather low compressive strength Nitomortar HB;
mortar, feature lightweight
will be developed) Renderoc HB; HB25
Polymer modified repair Suitable for concrete repair. It can be Unicell 25; Unicell 40,
mortar for high build with applied in thick section and is suitable for and unicell ultra
different classes of strength structural and non-structural application. rapid.

Types of Mortar (Cont’d)

Rapid Setting
Rapid setting Specifically developed for
Emaco S90UW
underwater mortar underwater repair and restoration work.
Rapid setting Rapid patching and plugging of concrete Renderoc Plug 1; Renderoc
waterstopping mortar segments. Plug 20 (20mins setting)

Types of Mortar (Cont’d)

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Types of resin-based mortars Suitability Reference

Expoxy resin mortars
Expocrete
Two-part epoxy resin mortars Low slump for general repair work
GP
(possesses outstanding strength and For use in exceptionally wet conditions and
Expocrete
adhesive powers) for underwater applications
UA
High strength, abrasionresistant For fast and permanent reinstatement of Nitomortar
epoxy reinstatement mortar concrete S
Polyester resin mortars
For fast and emergency reinstatement of
Polyester resin mortars with high
concrete, bedding, jointing and reprofiling Nitomortar
strength jointing and multipurpose
of concrete (cannot be applied to damp or PE
repair compounds
wet surface)

8 tests on Repair Mortar:

• compressive strength (28 days) 30-60 MPa

• Tensile strength (7 days) 2 MPa
• Mod of Elasticity (28 days) 15-25 kN/mm2
• Bond Strength (7days) 2.0 MPa
• Shrinkage Cracking (7 days) Coutinho ring test
• Permeability
• Workability
• Chemical Analysis
• Open-up inspection: 1 / 25sm patch repair
• Pull-off test (bond coat adhesion strength): 1/ 50sm patch repair
– Pass if 1/2 fracture in substrate or pull-off stress > 1/4 of the 7-day bond str
– Core a 75mm dia. Full thick of the repair with 7days age.

Bond Strength of Patch Repair – tested by pull-off test

• Pull-off test on the adhesion strength of the bond between the repair mortar and the
substrate concrete, aided by any bond coat
• identify re-bar position
– Repair area shall have a minimum age of 7 days
– Re-bar sensor to identify the location of reinforcement bars

Core

• A 75mm dia. Core containing the full thickness of the repair was produced

Dummy

• A suitable metal plate was glued to the cored hole and let it dry for one hour;
• this attachment was pulled with increasing tensile force using a calibrated device until
failure occurs.

Result 1

Criteria:

– fracture shall be at least half in the substrate concrete, unless

– the pull-off stress is not less than 1/4 (i.e. 0.5 MPa) of the minimum 7 days bond strength of
the repair mortar (2.0 MPa).

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Result 1

– Fracture at bond surface, bond strength = 27psi (0.9 MPa) – PASS

Result 2

• Half of the fracture at substrate, bond strength = 18psi (0.6 MPa) – PASS

Results 3 & 4

• Result 3: less than half of the fracture at substrate, bond strength = 12psi (0.4MPa) – FAIL
• Result 4: fracture at surface material, bond strength = 9psi (0.3 MPa) – FAIL

2. Recasting

• In this method, the damaged part of the structural element will be demolished, replace
corroded reinforcement and recast it with same or even better grade concrete in order to
restore its structural strength.
• Considerations for practical uses
• Pay attention to the discontinuity which causes any instability to the linked structural
elements due to demolition.
• Dowel bars and/or replacement steel bars should be placed on the cleaned reinforcement
bars.
• For recasting of slabs, evacuation may be required for flats above or below the element.
• The joint between old and new concrete should be paid with special attention. Poor joints
will result easy seepage of water and causes of corrosion.
• Shear key is required for large areas of recasting.
• Pre-soaking of substrate is necessary
• Avoid air trapping by thorough compaction of repair mortar.

Recasting by form and pump

• Application ranges
• When defective depth is ranges from 75mm to 100mm.
• Also for vertical members e.g. wall and column.
• When structural restoration is required.

3. Sprayed Concrete

• Sprayed concrete is a technique which is widely used in high-volume concrete repair work.
• The concrete mix will be sprayed with or without admixture or polymers to the defected
areas under high air pressure. This process can be done by means of nozzle gun.

Dry Spray Concrete

• There are two different methods of spraying:

– Dry process spraying
– Wet process spraying
• Dry process spraying is the process which the mixture of damp sand and cement is passed
through the delivery hose to the nozzle and the water is mixed at that time.
• This process is often used for repair work.
• It is because of its fast application process and restoration of structural strength at an early
stage.
• The performance characteristics of dry sprayed concrete are they have good density and
high strength.
• It has very good bond to a suitable substrate.

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• These advantages make it more variable than conventional concrete and wet process
sprayed concrete. (SCA, 1999)

Wet Spray Concrete

• Wet process spraying means all the ingredients including water are mixed together before
transporting to the site for repairing works.
• It is not normally applied for building repairs since the size of equipment is much larger
than that of dry process spraying.

Cracks prevention

• Concrete surface must be reinforced with small-mesh small diameter reinforcement before
carrying out sprayed concrete. This can prevent developments of cracks when the concrete
shrinks.

Spray Concrete

• Considerations for practical uses

• The process should be in a continuous process.
• Concrete mixed should be complied with acceptable standard and quality.
• The operation should be carried by experienced nozzleman.
• Acceptance test should be carried out to test the skill of the nozzleman.
• The process should be held at right angle to and at one meter from the surface of the repair
areas.
• Min. spray concrete thickness should be considered before spraying process.
• Reference should be made to Code of Practice for Structural Use of Concrete.
• Good surface preparation should be done.
• Sufficient safety precautions must be taken.
• Application ranges
• Large areas of repairs with thickness > 50mm
• In vacant flats and/or public areas, this can minimize the nuisance to peoples.
• Partial strength is to be restored.

Types of
Suitability Reference
sprayed concrete
Dry Spray
For large area repairs (rather low
Renderoc DS (aggregates
Polymer modified compressive strength developed) Should
used are classified as ‘non-
cementitious repair not be used when the temperature is <5C
reactive’.); Renderoc SC;
mortar and falling. Should not be exposed to
Optimix RM770
moving water.
Specially prepared for use in dry shotcrete
Gunite mortar
applications. (compressive strength: 30-40 Sika Rock 30
(cementitious based)
N/mm2)
Wet Spary
General concrete Sika Mono Top-612;
repair work Optimix RM770

Other Repair Methods

– Micro-concrete
– Pre-packed concrete
– Non-Shrinkage Grout
– Joint Sealing System

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1. Micro-concrete

• By applying this method, the contaminated or damaged concrete are removed and replaced
by fluid micro-concrete.
• It is used to re-form desired concrete profiles.
• Usually, prescribed mixes are available in the market with shrinkage compensators to
control shrinkage in plastic and hardened states.
• Considerations for practical uses
• It needs special design by the supplier and specialist advice is required.
• Formwork with leakproof is required.
• Pre-soaking of the formwork and substrate is required.
• Aggregates used should not be greater than 10mm.
• In order to improve workability, aggregates should be rounded in size.
• Good curing of the repair is essential.
• Application ranges
• For use in area with limited working space or congested reinforcement
• For use in thin sections where the use of normal concrete is impractical

Types of micro-concrete Suitability Reference

For area where access to the repair zone is restricted or
where reinforcement is congested which unable to carry Renderoc
Shrinkage compensated
out compaction and vibration. Difficult access which LA
make hand/trowel-applied mortars impractical.
High
Renderoc
performance shrinkage
LA55
compensated
Low alkali, non- Renderoc
reactive micro-concrete LA27

2. Pre-packed Concrete

• Graded aggregates similar to the substrate concrete will be placed firstly in the formwork.
• After the placement of graded aggregates, cement grout will be injected into the formwork from
THE BOTTOM.
• The resulting concrete will be in excellent quality in proper implication.• Considerations for
practical use • All loose and spalled concrete should be repaired prior to the application.
• Target compressive strength of the pre-packed concrete should be compatible with that of the
substrate.
• Trials on compressive strength before operation are recommended.
• Careful design on aggregate size and grading is recommended.
• Aggregate size shouldn’t be too fine in order to avoid blockage of grout patch.
• Similar to micro-concrete, formwork with leakproof is required.
• Pre-soaking of the substrate with water is necessary.
• Aggregate should be clean and free from silt before application.
• Application ranges
• For use at areas where concrete placing is difficult, e.g. at beam soffits.
• For areas with congested reinforcement or depth of repair is greater than 75mm where patch
repair is not suitable.
• For where the structural strength have to be restored.
• Advantages
• Compare to sprayed concrete, it has greater density, greater uniformity, lesser permeability,
lower shrinkage, less dependence on personal skills of equipment operators, less dust, less clean-
up work, and more economical.
• Limitations
• All works in vertical surfaces require formwork. At least 3 to 4 inches of space is required for

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replacement.

3. Non-shrink grout

• cementitious, epoxy resin or polyester resin based

• In repair works, non-shrink grout is used in crack injection repair.
• Also, it is used to repair porous concrete and in those areas with very congested reinforcement.
• Usually, it has a very high workability, it can be applied either flowable or in fluid.
• If mixtures are according to specified instruction, the compressive strength of non-shrink grout
can be higher than 50 N/mm2 although it has high workability.

Non-shrink grout

• Considerations for practical use

• Please refer to micro-concrete
• Application ranges
• used in crack injection repair,
• To repair porous concrete,
• Very congested reinforcement or in limited working spaces,
• Thickness of repair is thin.

4. Joint Sealing System

• This system is generally applied for repairing active cracks.

• The crack must be widened and sealed as joints if any measurements or circumstances
suggested that it is live crack.
• When those live cracks cannot successfully be glued together with resin injection, the joints
must be widened at the surface and sealed as a joint.

Types of joint
Suitability Reference
sealing system
For joints and cracks subject to normal or
Versatile sealing system Sikadur Combiflex
large movements
Joint sealing compound Permanent elastic one-compound
Sikaflex PRO 2HP
(Polyurethane base) joint sealing compound
One component
As an elastic adhesive and elastic
polyurethane sealant/ Sikaflex-11FC
joint sealant.
adhesive
Sealing of waterways Fast setting, Used
ERTOBLOC 224;
Instant- underwater High resistance to pressure.
Ronabond PU 10;
settinghydraulicmortar/ Some of the products are with different
Ronabond PU 20 (High
grout properties, such as, high strength, flexible
strength); Ronabond PU
and elastic for use in different situation.

Protection Methods

• Protective Coating
• Apply Cathodic Protection
• Provide Additional Concrete Cover
• Realkalization or Desalination
• Overcladding and Insulation
• Protection with Corrosion Inhibitors

5. Protective Coating

• The protective coating is a thin outer layer which used to protect the substrate concrete by
acting as an impermeable barrier or slowing the rate of penetration of active components from

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the surrounding environment.

• Three main functions of protective coating are:
– Change appearance;
– Improve surface properties;
– Barrier against the penetration of aggressive gases, liquids and vapours.
• Good protective coating should allow water vapour to pass out through it in order to stop the
building up of vapour pressure in the substrate concrete which causes blistering. (BSIS)
• Considerations for practical use
• Good surface preparation before application of the coating, such as completed repairing of
concrete and removal of surface contaminations and voids.
• Remove all loose part of existing painting and check the compatibility of the existing paints
before application.
• If a solvent based protective coating is selected, it should be in an open space with good
ventilation for coating to evaporate.
• Application ranges
• It should be applied on repaired concrete substrate to prevent further deterioration.
• In those areas where frequent wetting of concrete surface is unavoidable.
• On surfaces where exposed to aggressive surroundings.

Types of
Suitability Reference
protective coating
Single component epoxy As an anti-corrosion primer for
Nitoprime Zincrich;
zinc primer (corrosion exposed steel reinforcement for use
Frianzinc EPE
protection) with concrete repair mortars
Protection and enhancement of
Acrylic resin protective Sikagard 680 S-Concrete
concrete and asbestos cement
coating for concrete Cosmetic
building elements, especially facades.
Protective coating with
As a barrier to resist chemical Sikagard-62; Ronabond
moderate chemical
resistance, such as carbon ion. Cover Plus 150
resistance
Provides an effective barrier against SikaTop Seal 107; Ronabond
Waterproof protective the transmission of liquid water. It Joltec Finish; Ronabond
coating should be applied on concrete, Jotec Transparent;
brickwork and blockwork. Ronabond Nigatex

6. Cathodic Protection

The purpose of applying cathodic protection is to stop the setting up of anodes on the
reinforcement by applying a low voltage electric current or by a sacrificial anode.

Sacrificial Anode System

There are two main systems of cathodic protection:

– Sacrificial Anode System
– Impressed Current System

In sacrificial anode system, the steel is connected to a metal which is less stable in electro-
chemical series, e.g. zinc. Since zinc is more anodic than steel, the current will flow from zinc to
steel and zinc will be corroded instead of steel.

Impressed Current System

In impressed current system, an external current with sufficient intensity is applied to over-ride
the corrosion current.

Pros and Cons

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Advantages:

– The only way to completely stop steel corrosion

– Permanent solution

Disadvantages:

– Ongoing cost to maintain

– Many structures not suitable (access, noncontinuous reinforcement, pre-stressing steel, etc.)

Cathodic Protection

• Considerations for practical use

• Installation and maintenance costs for the systems are much higher than other repair methods.
• It needs special design by the supplier and specialist advice is required.
• Defects must be repaired before implication of cathodic protection.
• Electrical continuity has to be assessed before implication.
• Application ranges
• In area where corrosion is active or chloride content is high.
• Recasting or large scale patch repair is not feasible.
• Corrosion of steel reinforcement is not that serious while application.

Types of cathodic protection Suitability Reference

Sacrificial Anode System
Galvashield
For pre-stressed/post tensioned
Drilled in sacrificial anode for CC45,
structures (Not for use with epoxy and
reinforced concrete structures Galvashield
polyester repair mortars or primers.
CC65
To be embedded within
Embedded zinc anode which acts to repairs performed in chloride
prevent corrosion of reinforcing contaminated concrete to protect Galvashield XP
steel in concrete: adjacent steel from the onset of
corrosion.
Impressed Current System
For protection of steel corrosion in
Discrete cathodic protection anodes reinforced concrete Ebonex
structures and steel framed buildings

Realkalization

Advantages:
– Based on reversing the principles of cathodic protection
– Limited concrete removal
– No ongoing maintenance

Disadvantages:
– Very high installation cost
– Not all structures are suitable
– Environmentally unsound

Overcladding

Advantages:
– Greatly improves appearance
– Provides the additional benefit of insulation
– Provides a long-term solution

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Disadvantages:
– Very expensive
– Can hide latent defects
– Extended contract period

The Jardine House case

Corrosion Inhibitors

See Sika FerroGard-903 Corrosion Inhibitor or Tyfo CIS Inhibitor

Tyfo® CIS Inhibitor Layer 2

DESCRIPTION

Tyfo® CIS Layer 2 is a single-component, clear, waterbased liquid with a mild odor. It may be
applied by roller or spray following the application of Tyfo® CIS Layer 1. Layer 2 controls the
pH,
purges and encapsulates water-soluble chlorides, fills voids in the concrete, and inhibits further
penetration of moisture. Layer 2 also acts as a contact corrosion inhibitor on the reinforcing
steel.
After receiving both Layers 1 & 2, the exposed surfaces are cleaned by washing with fresh water
or
by abrasive blasting. All exposed steel is then treated with the Tyfo® CB material and the
concrete
section is restored using Tyfo® P or Tyfo® PF as required.

USE

Tyfo® CIS Layer 2 is used with the Tyfo® Concrete Repair System on new or old concrete
surfaces
to seal porosity, increase compression strength, maintain pH, protect from acid and alkali
attack,
pacify and extract chlorides, and inhibit embedded steel corrosion.

ADVANTAGES

• Ease of application
• Can be applied to horizontal, vertical or overhead surfaces
• Restores properties of deteriorating Portland concrete cement
• Can penetrate concrete 2 to 3 inches, depending upon existing porosity
• Dramatically improves condition of substrate prior to repairs
• Protects new concrete
• For new and old structures
• Non-toxic

European Standards for Repair and Protection of Concrete

The standards related to the repair and protection of concrete of concrete currently available as
standards or under development by CEN TC104 SC8- Protection an Repair an Repair of
Concrete. It was updated on 6 November 2001.

State-of-the-art Repair and Protection Methods

Concrete
– Patch repair with phosphate-based
– Cathodic protection
– Chloride extraction

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– Concrete re-alkalization
– Concrete strengthening plates/sheets
– Surface-applied penetrating sealer and coating

Re-bar
– Fusion-boned epoxy bar coatings
– Inhibitive primer

1) Patch Repair: Magnesium phosphate-based

It is a unique, two-component with rapid setting concrete repair and grouting system. It cures
faster than concrete and it has a very good bonding with new and old concrete. The repair
system can be applied at any temperature without shrinkage and is freeze/thaw and deicing salt
resistant since it does not require water as an additive.

2) Concrete strengthening

An advanced technology of concrete strengthening techniques which do not need to recast the
concrete structure for strengthening.

This technique apply the use of placing an bonding CIFIRP (Fibre Reinforced Polymer) plates or
sheets to surfaces of structural concrete members

Examples of Concrete Strengthening Materials

Types of concrete strengthening Suitability Reference

Composite fabrics for structural Shear strengthening in a building beam and
SikaWrap
and seismic strengthening slab Flexural strengthening of slab
For structural strengthening for post-
Fibre reinforced polymer (FRP) Ronacrete
reinforcement of structural members, such as
system FRP system
beams, columns, slabs)

3) Chloride Extraction

If there is a presence of chloride ion, the concrete will deteriorate at a faster rate. It is mainly due
to the depassivating effect of chloride ions. Usually, a value of 0.8% (a critical acceptance value)
is adopted for practical use.

In this method, chloride ions are removed from concrete by dissolving in electrolyte and drawing
it to an external electrode by an electrical potential. The external electrode being used in this
method is a titanium wire mesh which is embedded in electrolytic paste of cellulose fibre. The
paste is adhered onto the surface of concrete.

4) Concrete Re-alkalization

Alkaline is a substance which can protect reinforcement from corrosion. When concrete is
carbonated, its alkalinity decreases and hence the protection of reinforcement is decreased. This
method is used by diffusing alkaline chemicals like metallic hydroxides into concrete for
increasing pH value and cause repassivation.

Recently, this technique is still under testing and not yet been developed for field test. Therefore,
it is difficult to find this service in the market.

5) Surface-applied Penetration Seal

Aquron® CPT-2000 is a highly reactive catalytic agent which reacts with free alkali and/or
alkaline hydrates by internally producing a silica hydro-gel which fills the pore spaces and the
voids around aggregate. Furthermore, alkali is converted to a neutral compound structure,

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reducing the potential for internal chemical reactions. More density is added, additional bonding
strength is provided and concrete is permanently hydrostatically sealed from within.

– prevents ingress and migration of moisture and damaging corrosive

– Deplete soluble chlorides in concrete and inhibit corrosion of imbedded reinforcing steel

6) Corrosion Inhibitor

• With the addition of calcium nitrite, the standard threshold of corrosion is elevated
• i.e. the protective passivity layer can tolerate a higher level of chloride ions.
• http://www.na.graceconstruction.com/concrete/

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