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Construction and Building Materials 236 (2020) 117445

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Construction and Building Materials


journal homepage: www.elsevier.com/locate/conbuildmat

The effectiveness of ethyl silicate as consolidating and protective coating


to extend the durability of earthen plasters
Victoria E. García-Vera a, Antonio J. Tenza-Abril b, Marcos Lanzón a,⇑
a
Departamento de Arquitectura y Tecnología de la Edificación, Universidad Politécnica de Cartagena, 30203 Murcia, Spain
b
Department of Civil Engineering, University of Alicante, 03690 Alicante, Spain

h i g h l i g h t s

 Ethyl silicate significantly improves the physical resistance of earthen plasters.


 Water absorption properties are clearly enhanced with ethyl silicate coatings.
 Earthen plasters present limited durability against rain water and acid rain.
 Ethyl silicate-treated samples show much better resistance to acid rain.
 The plasters’ porosity is substantially reduced with ethyl silicate coatings.

a r t i c l e i n f o a b s t r a c t

Article history: In the heritage protection, one of the most interesting scenarios is the preservation of the original mate-
Received 15 May 2019 rials. In this case, the surfaces are generally treated to consolidate them. The aim of this paper is to eval-
Received in revised form 8 October 2019 uate the effect of ethyl silicate coatings on surface consolidation, water absorption and porosity of
Accepted 2 November 2019
earthen materials. Peeling tests, water absorption measurements (capillary and Karsten) and textural
alteration analyses were conducted by optical microscopy. In addition, the protective role of the ethyl sil-
icate coatings against rainwater, HCl rain and H2SO4 rain was evaluated to compare the durability of
Keywords:
coated and control samples. It was found that ethyl silicate substantially improved the above properties
Earthen plasters
Ethyl silicate
as well as microstructural features of the samples. Scanning Electron Microscopy and EDX mapping
TEOS revealed the coating was not regularly spread on the surface. Despite this, Mercury Intrusion
Consolidation Porosimetry tests showed the total porosity of samples coated with ethyl silicate was clearly reduced.
Acid resistance Ó 2019 Elsevier Ltd. All rights reserved.
Durability
Microstructure

1. Introduction cess. For this reason, further research is needed to ascertain the
performance of protective coatings (e.g. ethyl silicate [3,4], sodium
Earth-based constructions are traditional solutions for building silicate [5], hydroxyapatite [6], nanolime [7], oils [8]) in front of
because of their availability and easy handling. Nowadays, there water and acid rain aggressions. This study is focus on ethyl silicate
are historical earthen constructions that are relatively well pre- applied on earthen plasters.
served, despite anthropogenic and weathering factors. These con- The most damaged areas of earthen plasters in historical con-
structions are part of our cultural heritage and must be structions are usually rebuilt. In this case, the materials used in
preserved to leave this legacy to future generations. Earthen mate- the reconstruction might be manufactured with stabilisers (i.e.
rials by their own nature are weak and consequently very sensitive lime, cement, wastes, fly ash or coal ash) to enhance their proper-
to external agents, such as pollutants and atmospheric effects, ties, such as increase mechanical strength, decrease erosion against
especially rain [1,2]. These agents cause decay processes including rain and water absorption, and increase water vapour permeability
a significant softening and deterioration on the surface. Therefore, [8–10]. However, from the heritage point of view the most inter-
as regards earthen materials exposed to outdoor environments, the esting scenario is the preservation of the original materials. In this
use of protective treatments is beneficial to delay the above pro- case, the materials are generally consolidated with the aim of
strengthening eroded zones on the surface. Both in the restoration
⇑ Corresponding author. process and consolidant selection, close attention should be paid to
E-mail address: marcos.lanzon@upct.es (M. Lanzón).

https://doi.org/10.1016/j.conbuildmat.2019.117445
0950-0618/Ó 2019 Elsevier Ltd. All rights reserved.
2 V.E. García-Vera et al. / Construction and Building Materials 236 (2020) 117445

avoid undesired effects [11,12] such as surface glazing, chromatic rainwater, HCl rain and H2SO4 rain simulation. Furthermore, Mer-
change, water vapour permeability decrease. cury Intrusion Porosimetry (MIP) analyses were performed to
According to [13], the preservation of historical heritage is still assess the microstructural variations induced by the treatment in
based on conventional techniques and products, usually charac- the pore system. Finally, the surface of treated and control earthen
terised by a lack of compatibility with the substrate to be treated, plasters were examined with Scanning Electron Microscopy (SEM)
and by low performances under environmental conditions. How- using EDX mapping analyses.
ever, modern techniques and products are accepted by Venice
Charter [14], which includes the use of any modern technique for 2. Materials
conservation and construction when more suitable for conserva-
tion. On the other hand, the chemical industry has been studying Each specimen was made with a clayey binder, a mix of two
and manufacturing waterproofing and consolidants since the limestone sands (A and B) and distilled water. The raw materials
beginning of the 20th century to prevent the decay of architectural and the final paste of this study were analysed in a recent study
heritage [15]. At present, nanomaterials are being studied for the [28]. Two types of clayey binders (yellowish and reddish) were uti-
conservation and restoration of building heritage. These nanoma- lised which are commonly employed in the manufacture of
terials can act as consolidants (inorganic nanomaterials and extruded fired bricks. These clayey binders are usually named with
silicon-based hybrid polymer nanocomposites), water repellents the word clay in the industry. Henceforth, in this context the terms
or as protective treatments (self-cleaning coatings and antimicro- binder and clay will be indistinctly used to refer to any type of
bial coatings) [16].These consolidants have been applied mainly clay-based binders. The binders have been studied by X-ray diffrac-
on stony materials but little has been studied on earthen materials. tions (XRD) confirming the existence of quartz, gypsum, calcite,
Among the actions aimed at using consolidating materials, [17] muscovite and kaolinite as main minerals. Similar X-ray fluores-
shows that silicon-based consolidants (such as ethyl silicate, cence (XRF) studies have found SiO2 (43.9%) and Al2O3 (16.8%) as
sodium silicate or colloidal suspensions of silica) may deposit a major components of both binders. Finally, the thermogravimetric
gel of amorphous silica within the pores of stone. This gel strength- analysis showed the yellow binder has higher carbonate concen-
ens the surface of the material and increase its acid resistance due tration (20.1%), most likely associated to calcite and dolomite, than
to deposition of SiO2 gel, which is not attacked by acid rain and pro- the red binder (8.6%), being the H2O concentration similar for both
vides certain hydrophobicity by blocking pores of the material. An binders, yellow (2.1%) and red (2%). Also, the Atterberg limits were
additional advantage of inorganic consolidants is that they are more obtained, for the red clay, the plastic limit, liquid limit and plastic-
compatible with the substrate although they have worse cohesion ity index were 18.9, 29.5 and 10.6 respectively, and for the yellow
properties than the organic ones [17]. Despite the current interest, clay 19.2, 33.5 and 14.3.
the use of the aforementioned consolidants (ethyl silicate, sodium The particle size distribution study of the sands was carried out
silicate, and colloidal suspensions of silica) is not a novelty of the according to the UNE-EN 933-1 standard [29]; for sand A, the max-
last years in the heritage restoration, because they were already imum size (D) was 0.5 mm, the minimum size (d) 0 mm and the fil-
used in the 20th century for the consolidation of stones [18]. ler percentage 0.18% (filler defined according to [30] as the
Other than silica-based consolidants have been used on stone percentage passing through the 0.063 mm sieve); for sand B the
materials, such as calcium alkoxides [19], hydroxyapatite [6], oxa- values found were: D = 4 mm, d = 0.125 mm, filler = 0.04%. The par-
lates [20], etc. Nevertheless, ethyl silicate (i.e. tetraethyl orthosili- ticle size distributions of the binders were determined by laser
cate or TEOS) is currently the consolidant most extensively used on diffraction (Fig. 1). The dosage used was: 10 wt% binder, 30 wt%
stones [4,15], which has been used since the beginning of the 20th sand A, and 60 wt% sand B. Water was added to this mixture
century not only as consolidant on stones but also as binder for obtaining 0.16 ratio of water to solid. This dosage has been utilised
ceramics, adhesive for coverings in precision casting, raw material in previous studies [1,28,31,32] leading to minimal shrinkage dur-
for obtaining amorphous silica, gelling product to obtain alcohol ing the samples hardening. Estel 1000Ò (CTS Spain), a commercial
fuels, and in the preparation of glass adherent lacquers [21]. Ethyl consolidant with a 75% of tetra-ethyl-ortho-silicate (TEOS) as active
silicate, in addition to being used on stones with good results ingredient, was used as consolidating treatment.
[12,19,22], has also been applied successfully in the consolidation
of bricks [15,23] and lime mortars [24,25]. 3. Methods
The consolidation of earthen plasters has been little studied.
However, some examples have been found in the scientific litera- 3.1. Samples preparation.
ture, such as the earthen finishes at Mesa Verde national park of
Colorado that were consolidated with alkoxysilanes and gelatin Two types of specimens were manufactured to meet the needs
[26]. Also, treatments indicated to protect the surfaces of porous of the tests performed, prismatic specimens using standardised
building materials against weathering (silicon nanoparticles, tita- moulds for cement mortars (4  4  16 cm), and 1 ± 0.1 cm thick
nia and silica nanoparticles, silane–siloxane, beeswax) were used plasters were applied on ceramic surfaces (12  24 cm) (Fig. 2a,
for the consolidation of earthen plasters [27]. In addition, nanolime 2b and 2c). The specimens were stored for seven days under labo-
has been applied successfully for the consolidation of other earthen ratory conditions (24 ± 2 °C) and then dried at 60 °C for 24 h to
materials such as adobes [1]. However, more research on the con- accelerate the process of water evaporation and densification of
servation and consolidation of earthen materials is needed, since it the mixture. After that, the samples were kept for 1 h under labo-
is a material widely used in the construction of historic buildings ratory conditions to acclimatise, and then the ethyl silicate (Estel
(e.g. Alhambra of Granada, Roman theatre of Cartagena, Punic wall 1000Ò) treatment was applied. This consolidant reacts with the
of Cartagena). atmospheric humidity and is transformed into silica gel SiO2
This study focuses on the use of ethyl silicate in the consolida- releasing ethanol. A single coat of ethyl silicate was applied on
tion of earthen plasters. The aim of this study is to evaluate the the surface with the aid of a nebuliser at a distance of 20 cm from
consolidation effects of the ethyl silicate (ES) on earthen plasters. the surface (Fig. 2e). Cardboard frames were used to delimit the
For this purpose, a set of specimens treated with ES and control area where the treatment was to be applied (Fig. 2d). Once the
samples were studied. To evaluate the consolidating effectiveness, treatment was applied, the samples were kept for two weeks in a
several tests were conducted including peeling test (also called humid chamber at 80% ± 2% RH, and at the end of this period they
Scotch tape test), water absorption, durability tests consisting of were reintroduced in the oven at 60 °C for 24 h.
V.E. García-Vera et al. / Construction and Building Materials 236 (2020) 117445 3

Fig. 1. Particle size distribution of the red and yellow clay. (For interpretation of the references to colour in this figure legend, the reader is referred to the web version of this
article.)

Fig. 2. (a) process of plaster preparation; (b) red plaster samples; (c) yellow plaster samples; (d) plaster covers with cardboard frames to apply the treatment; (e) nebuliser
used to apply the ES treatment. (For interpretation of the references to colour in this figure legend, the reader is referred to the web version of this article.)

3.2. Peeling test 3.3. Water absorption tests

The level of consolidation of the studied plasters was assessed The water absorption capacity of the plasters was evaluated
with the peeling test (Fig. 3a, 3b, and 3c). This technique can be using a modified version of the UNE-EN 772-11 standard [28,36].
performed in situ and under laboratory conditions and it is suitable This modification prevents samples collapse to happen due to the
for assessing the cohesion qualities of paint films, stones, historic water action by placing the specimen on a wet towel (Fig. 3d).
renders and plasters [33–35]. The method measures the amount The mass variation per unit of area of the sample as a function of
of material adhered to a flexible adhesive tape (5  2 cm) which square root of time is monitored. The absorption coefficient was
is attached to the tested surface and then removed (Fig. 3c). The obtained from the slopes of the curves using linear regression anal-
detached material is calculated as the difference between the orig- ysis [28,37,38]. The water absorption capacity was also assessed
inal and final weight of the tape. Therefore, the amount of with the Karsten test that simulates the water penetration due to
extracted material reflects the cohesion of the substrate and can water column pressure. The test can be performed either in situ
be used to evaluate the effects of consolidation after restoring or laboratory conditions in a wide set of materials, such as stone,
the surface [12]. Three plasters were manufactured for each type brick and renders [39,40]. A graduated tube is fixed to the surface
of clay (Fig. 2b and 2c). The samples were divided into two areas, with an adhesive to avoid water leakage and filled with water. The
one without treatment (control) and another with the ethyl silicate absorbed water was measured periodically until the 4.5 cm3 mark
(ES) treatment. Three regions were chosen on the surface and 10 on the tube was reached, then the water absorption coefficient
peeling tests were performed on them so that 180 tests were car- (WAC) was obtained by linear regression from the slope of the
ried out in total (90 coated samples + 90 control samples). curves.
4 V.E. García-Vera et al. / Construction and Building Materials 236 (2020) 117445

Fig. 3. (a and b) preparation of the adhesive strips to carry out the peeling test; (c) 5x2 cm adhesive strip glued to the plaster surface; (d) modified method of the UNE-EN
772-11 standard [36] to measure capillary water absorption for earthen materials; (e) devise used to perform the durability tests (simulation of rainwater, HCl rain and H2SO4
rain).

3.4. Durability tests microscope was equipped with polariser filter to eliminate possible
light refections and the images were captured in high-resolution.
The tests to evaluate the resistance to the action of rain, HCl rain
and H2SO4 rain were conducted by dripping the specimens (control 4. Results and discussion
and treated) from a container at a constant height for 10 min
(Fig. 3e). The dripping speed was approximately one drop every 4.1. Consolidation treatment: peeling test
5 s. The action of rainwater was simulated dripping distilled water
and the action of acid rain was simulated dripping two types of The peeling test results (Fig. 4) show that the yellow plaster has
acid solutions: sulphuric acid solution H2SO4 0.9 M and hydrochlo- higher consolidation efficiency than the red plaster, since the
ric acid solution HCl 0.6 M. Twelve specimens were made for each detached material for the red plaster was 50% higher (871.3 mg/
clay formulation and treatment i.e.12 control specimens and 12 cm2; RSD 17.8) than that of the yellow one (405.9 mg/cm2; RSD
treated specimens with ES. Therefore, four specimens were used 19.2). The effectiveness of the treatment was important in both
in each rain simulation experiment. After dripping the specimens, plasters: 94% (52.9 mg/cm2; RSD 13.3) and 92.5% (30.4 mg/cm2;
they were gently brushed in order to remove non-adhered rests of RSD 16.5) for the red and yellow plasters, respectively. The results
eroded material on the surface. The specimens were weighed are coherent with other studies [17] conducted on stone where
before and after being dripped to obtain their mass variation due ethyl silicate also improved the surface cohesion. The ethyl silicate
to rain action. effectiveness is higher than that achieved by Ca(OH)2 nanoparticles
coatings when the treatment is evaluated for similar earthen mate-
rials (adobe) [1]. The good performance of the ethyl silicate is due
3.5. Mercury Intrusion Porosimetry (MIP)
to the amorphous silica gel, produced by the chemical reactions of
the ethyl silicate with the atmospheric humidity that strengthen
MIP is commonly used to assess consolidation efficiency
the surface of the material.
[12,17]. Hence, the microstructural properties of control and trea-
ted plasters were studied by MIP using a Poremaster-60 GT
4.2. Capillary water absorption tests
porosimeter. The technique allows obtaining information about
the pore structure of materials with accessible pores ranging from
The water absorption coefficient (WAC) was calculated as the
4 nm to 900 lm. The MIP analyses were conducted on samples
regression line slope. The results (Fig. 5) showed that both clay-
taken from the surface of plasters and the working conditions var-
ied from atmospheric pressure to 60.000 psi (413.7 MPa). Four
samples were analysed: red plaster (1.0758 g; 0.5343 cm3); coated
red plaster (1.7526 g; 0.8490 cm3); yellow plaster (1.2883 g;
0.6584 cm3); coated yellow plaster (1.2610 g; 0.6078 cm3).

3.6. Scanning electron and optical microscopy

Semi-quantitative analysis (mapping) and morphology exami-


nation of the samples were studied by Scanning Electron Micro-
scopy (SEM) (Hitachi S-3500N) equipped with an X-ray detector
Bruker XFlash 3001 for microanalysis EDX. The fragments were
extracted from control and coated plasters and dried at 60 °C for
24 h. The working conditions in SEM were 20 kV using back-
scattered electrons (BSE mode) and a working distance of 15 mm.
Moreover, an optical microscope (Dino-Lite Edge) was used to
study the physical changes on the surface produced by rain. The Fig. 4. Material adhered on the adhesive tape strips used in the peeling test.
V.E. García-Vera et al. / Construction and Building Materials 236 (2020) 117445 5

Fig. 5. Capillary water absorption of the red clay plaster (a) and yellow clay plaster (b) using a modified method of the UNE-EN 772-11 standard [36]. (For interpretation of
the references to colour in this figure legend, the reader is referred to the web version of this article.)

based plasters have similar WAC (red-clay plaster: 0.67 kg/


m2∙min0.5; yellow-clay plaster: 0.60 kg/m2∙min0.5). The ES treat-
ment reduced WAC in both plasters (0.39 kg/m2∙min0.5 for the
red-clay plaster and 0.3 kg/m2∙min0.5 for the yellow one). The
WAC reduction is consistent with previous studies performed on
limestone materials treated by ethyl silicate [41]. The yellow-clay
plasters showed lower water absorption, for both control and trea-
ted samples, which might be due to two reasons. Firstly, the red
binder was mainly composed of clay-based minerals often suscep-
tible to absorb water, and therefore, they increase the water capil-
lary uptake. Secondly, the greater presence of calcitic phase
(CaCO3) in the yellow binder (clearly identified with larger peaks
in the XRD analysis [28]), which is associated with lower water
absorption.

4.3. Water absorption: Karsten tube

The Karsten water absorption (KWA) was also studied from the
slope of regression lines, calculated over the entire time interval
shown in Fig. 6. The KWA data were similar for both plasters
(red-clay plaster: 5.38 kg/m2∙min0.5; yellow-clay plaster: 4.87 kg/ Fig. 7. Tests of water absorption using Karsten tubes. (a) test conducted on the red
m2∙min0.5). After applying ethyl silicate, KWA was reduced in both clay plaster without treatment; (b) test perfomed on the red-clay plaster treated
materials (red-clay plaster: 1.80; yellow-clay plaster: 1.84). When with ethyl silicate. (For interpretation of the references to colour in this figure
legend, the reader is referred to the web version of this article.)
the test was conducted on control plasters the material was dis-
solved by water and partially filled the Karsten tube (Fig. 7a) [2].
However, when the test was performed on the surface treated with observed for HCl rain simulation, followed by distilled rainwater
ES, the decaying effect of the surface did not occur (Fig. 7b) due to simulation and, finally, H2SO4 rain simulation [28], the RSD for
the consolidating properties of the treatment. the control samples ranged between the values of 5.9% and
10.3%. An important finding of the study is that ethyl silicate signif-
4.4. Durability tests: rain simulation icantly improved the rain resistance in all cases (water, HCl and
H2SO4), the RSD for the treated samples ranged between the values
The durability tests confirmed that earthen materials are sensi- of 5.1% y 16.8%. It must be emphasised, however, that for the H2SO4
tive to the action of rain water and acidic environments (Fig. 8). simulation the weight of the specimens increased due to gypsum
The control plasters behaved similar and the highest erosion was formation on the surface [32,38,42].

Fig. 6. Water absorption using Karsten tubes. (a) red-clay plaster, and (b) yellow-clay plaster. (For interpretation of the references to colour in this figure legend, the reader is
referred to the web version of this article.)
6 V.E. García-Vera et al. / Construction and Building Materials 236 (2020) 117445

Fig. 8. Percentage of mass variation in plasters exposed to rainwater, HCl rain and H2SO4 rain for the red clay plaster (a) and yellow clay plaster (b). (For interpretation of the
references to colour in this figure legend, the reader is referred to the web version of this article.)

Fig. 9. Colour and textural variations caused by rain (water, HCl and H2SO4) in red-clay plasters; (a) to (c) control plaster exposed to distilled water, HCl and H2SO4 rain; (d) to
(f) plaster coated with ethyl silicate exposed to distilled water, HCl and H2SO4 rain. (For interpretation of the references to colour in this figure legend, the reader is referred to
the web version of this article.)

The effect of rain was also examined by optical microscopy 4.6. Scanning electron microscopy
using a digital microscope equipped with image software (Dino
Capture 2.0). The effect of HCl and H2SO4 acid solutions was visible The objective of SEM-EDX examination was to determine
in non-treated samples (Fig. 9b and 9c). However, it is worth whether the ethyl silicate was distributed uniformly on the plas-
stressing the protective role of ethyl silicate in samples exposed ter surface. (Fig. 11). Since calcium is a major constituent in the
to all types of acid environments as shown in Fig. 9e and 9f. The studied plasters, the emission of the element was used to visu-
deposition of gypsum in samples attacked by H2SO4 acid was con- alise changes induced by ethyl silicate treatment, in which silicon
firmed by deposition of thin white rests on their surface (Fig. 9c is the major element. Using mapping analysis, the calcium signal
and 9f). Finally, HCl solution produced an important alteration on (X-ray emission) was represented in red whereas the silicon one
the surface of the samples where large cavities were observed, was displayed in blue. As shown in Fig. 11a, an important fraction
thereby confirming the results observed in Fig. 8. of the X-ray emission is due to calcium (aggregates) with a minor
contribution of the binding phase (clay). On the other hand, the
emission due to silicon (blue) is increased after applying the coat-
4.5. Mercury intrusion porosimetry ing (Fig. 11b), since the ethyl silicate transforms into silicon.
Moreover, this image shows the irregular pattern of silicon distri-
MIP data (Fig. 10) showed that the ethyl silicate treatment bution, revealing that the treatment did not cover the surface
decreased the total volume of pores in both plasters. In the red completely.
plaster the total pore volume was reduced from 0.1214 cm3/g (con-
trol) to 0.1044 cm3/g (ES coated), whereas in the yellow one a sim-
ilar reduction was observed (control: 0.1391 cm3/g; ES treatment: 5. Conclusions
0.1096 cm3/g). The predominant pore diameter in both plasters
was in the 10–100 mm interval, in which the porosity reduction The study confirms ethyl silicate improves physical and
was clearly reduced. In this interval, the pore volume was reduced microstructural features of the earthen plasters studied. There-
by 11.08% and 21.76% for red and yellow plasters, respectively. The fore, the durability of heritage materials like adobe, earthen
results are coherent with previous studies where ethyl silicate was plasters or tapial can be improved using the consolidant. Accord-
found to reduce the volume of pores in fired-clay bricks [23] and ing to the results obtained in this study, the following can be
limestones [41]. concluded:
V.E. García-Vera et al. / Construction and Building Materials 236 (2020) 117445 7

Fig. 10. Porosimetry study for (a) red-clay plaster (control and treated) and (b) yellow-clay plaster (control and treated). (For interpretation of the references to colour in this
figure legend, the reader is referred to the web version of this article.)

Fig. 11. (a) red-clay plaster without treatment; (b) red-clay plaster treated with ethyl silicate. (For interpretation of the references to colour in this figure legend, the reader is
referred to the web version of this article.)

 Ethyl silicate coatings consolidated the surface of earthen mate- impact of rainwater is due to the consolidating effect of the
rials and peeling tests confirmed a significant contribution of ES treatment, whereas in acidic environments the lack of reac-
the consolidant with effectiveness above 92%. tivity of SiO2 in front of HCl and H2SO4 solutions is a positive
 Both capillary water and permeability absorption of earthen factor to consider. The lower erosion observed with sulphuric
plasters were reduced by ethyl silicate coatings. This improve- acid solution is explained by formation of gypsum layers on
ment is beneficial for earthen materials due to the fact they the plasters’ surface
are highly sensitive to the water action. In addition, Karsten  Mercury Intrusion Porosimetry analyses showed that ethyl sili-
tube experiments demonstrated the consolidating effect of cate reduced the total volume of pores in earthen plasters,
ethyl silicate when applied on earthen materials surfaces. which is consistent with both capillary water absorption and
 Durability tests confirmed the protective effect of ethyl silicate Karsten tests.
coatings against rain, HCl rain and H2SO4 rain. The reduced
8 V.E. García-Vera et al. / Construction and Building Materials 236 (2020) 117445

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