US20060010819A1 - Retaining wall with plastic coated wooden panels - Google Patents
Retaining wall with plastic coated wooden panels Download PDFInfo
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- US20060010819A1 US20060010819A1 US11/197,973 US19797305A US2006010819A1 US 20060010819 A1 US20060010819 A1 US 20060010819A1 US 19797305 A US19797305 A US 19797305A US 2006010819 A1 US2006010819 A1 US 2006010819A1
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- United States
- Prior art keywords
- panels
- board
- edge
- structural
- panel
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- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
- E02D29/00—Independent underground or underwater structures; Retaining walls
- E02D29/02—Retaining or protecting walls
- E02D29/0258—Retaining or protecting walls characterised by constructional features
- E02D29/0266—Retaining or protecting walls characterised by constructional features made up of preformed elements
Definitions
- FIG. 1 is a perspective view of a section of a retaining wall, showing a vertical pile, a horizontal wale, and a series of panels supported by the wale, with a section of the plastic envelope of the pile removed to illustrate that the core of the pile is formed of wood, and with a portion of the anchor rod removed.
- FIG. 6 is a perspective view of a wall formed with the structural panels of the preceding figures, but with the panels oriented horizontally in the wall structure.
- FIG. 1 illustrates a retaining wall 10 that has been assembled for placement between a body of water 11 and a land mass 12 , for separating the water from the land. While only a portion of the retaining wall is illustrated, it will be seen that it includes a plurality of vertical piles 14 , horizontally extending wales 16 , and a plurality of elongated, vertically oriented structural panels 18 placed in edge-to-edge relationship.
- the piles 14 are oriented vertically so that they can be driven downwardly through the water 11 and into the earth below so that the lower end portions of the piles are embedded in the earth and remain stabilized by the earth.
- FIGS. 2-4 show the structural panels 18 .
- Each structural panel is formed of a wooden board or plank 40 that is optionally treated with chemicals that tend to reduce the rate of deterioration of the boards.
- the boards 40 are rectangular in cross-section and are elongated.
- a typical board used as a structural panel may be from one to four inches in thickness and from four to twelve inches in width. Other dimensions are available, depending on conditions such as the size of the boards needed at the job site, the supply of stock available to the manufacturer of the panels, and the price of the product.
- the example illustrated in FIG. 2 is a board that is two inches in thickness and eight inches in width, and is rectangular in cross-section and would be of a length as may be desired at the site where it is to be constructed, for example ten feet in length.
- the new panel 18 B when a series of panels have been driven into the earth 67 below the water 11 , the new panel 18 B will have its second edge 56 received in the U-shaped recess 65 formed by the lips 58 and 59 of the previous panel.
- the lips guide the new panel 18 B as it is being driven in the direction indicated by arrow 68 , so that the lips 58 and 59 , as well as the first edge 55 of the previously installed structural panel guide the new panel 18 B as it is being driven downwardly. This tends to guide the panels so that they will be connected together in a straight wall.
Abstract
Description
- This application is a continuation-in-part of co-pending U.S. patent application Ser. No. 10/891,930, filed Jul. 15, 2004 in the U.S. Patent and Trademark Office.
- This invention concerns retaining walls of the type used for retaining the earth at the water's edge of a body of water, particularly where the wall is to be exposed to harsh environmental conditions, such as extreme heat and cold, moisture, insects, abrasion, etc.
- Barrier walls can be formed of a plurality of elongated vertically oriented piles having their lower extremities driven into the earth to a depth sufficient to support the piles and their associated structural elements. Horizontally extending wales are mounted to the piles, and vertically oriented structural panels are partially driven into the earth adjacent the wales. Usually, the panels have interlocking male and female opposed edges that are used to connect to the edges of the panels together. Also, the male and female edges of the panels are used for guiding the next panel into position in the wall structure by engaging the male and female edges of the adjacent panels as the oncoming panel is driven into the earth. This causes the connected panels to form a continuous barrier wall.
- Because of the strength required for the panels when being driven into the earth and the strength required under the load conditions, the panels have to be strong. In the past, panels have been made of wood, and the wood can be cut to specific sizes for providing proper strength characteristics to the wall structure. However, wooden panels are subject to deterioration from marine borers and other insects, and rot and deterioration from impact by other objects. In order to avoid deterioration from rot and marine borers, wooden panels can be chemically treated. This slows the deterioration process of the panels from marine borers but provides the potential hazard of leaching of hazardous chemicals from the panels into the water and adjacent surroundings, possibly causing an environmental hazard. Also, wooden panels tend to shrink and/or swell in response to their environmental conditions. This tends to cause gaps between the panels in the wall structure, allowing water, silt and other undesirable elements to pass with water through the wall structure. In order to avoid the passage of material through the panels, wooden panels have been formed with tongue and groove edges that mate together in an attempt to reduce the ease of passage of the materials between adjacent panels. Another preventive measure is to use additional sheet material that is spread across the panels so as to retard movement of particles through the gaps between panels.
- More recently, retaining walls have been formed with metal panels, such as steel or aluminum that are stronger than wood. The metal panels have been formed in cross sectional shapes such as V-shapes, Z-shapes, etc. that provide lateral strength and stability to the panels. This enables the thicknesses of the panels to be reduced substantially so as to conserve on the weight and expense in forming and handling the panels. However, the shaped panels are sometimes considered undesirable because they do not present a flat surface that is more visually and structurally pleasing.
- At the present time, the most popular panels for the construction of retaining walls are extruded plastic panels. The panels formed of plastic have good compression strength properties so that they can be driven into the earth, but their lateral strength properties are weaker than the metal panels. In order to provide lateral strength to the panels, the V-shaped and Z-shaped profiles of the panels have been increased and the thickness of the panels has been increased.
- While the metal and plastic panels have been successful in avoiding deterioration by marine borers and other insects, the profiles of the panels are still objected to by many since they do not provide a pleasing, less industrial look like the flat panels.
- Recently, structural panels have been formed of wooden boards with plastic surfaces that form envelopes about the boards and protect the interior wood from marine borers, abrasion, moisture, etc. In some instances, the plastic material has been applied by spraying it onto the surface of wooden boards, as shown by U.S. Pat. No. 6,135,675, or by vacuum extrusion of plastic material onto the surface of the wooden boards, as disclosed in co-pending U.S. patent application Ser. No. 10/891,930. By providing the protective plastic surfaces to the wooden boards, there has been a beneficial result of reduction in deterioration of the panels from marine borers, better moisture control of the interior wooden boards of the panels, and reduced deterioration from impact, abrasion, and other external sources.
- However, the known panels made of wooden boards with plastic exteriors have not been successful in forming panels that are connected edge-to-edge to form a strong and continuous barrier that retards the movement of water and water-borne particles through the wall structure. U.S. Pat. No. 5,360,295 discloses the use of plastic tongue and groove edge attachments that are mechanically attached to the opposed edges of wooden boards, requiring attachments to both edges of the boards. This requires the manufacture of the two plastic edge attachments and the additional separate functions of attaching both of the edge attachments to the boards. Also, the tongues and grooves are formed with voids between the wood and the plastic material that forms the tongues and grooves, thereby forming spaces that can receive and hold water. The retention of water between the boards and their tongues at one edge of the panels and/or between the boards and their grooves at the other edge of the panels introduces the hazard of freezing of the retained water in the panels in cold weather and deterioration of the adjacent surfaces of the plastic and the wood of the panels. Also, PVC plastic, for example, is about one third as strong as wood and the connection of a plastic a tongue protruding from a board into a plastic groove also protruding from the adjacent board is a connection of the weakest portions of the boards that is more likely to fail under lateral stress than with board-to-board connection or with only one connector between adjacent boards.
- Thus, it would be desirable to provide an improved retaining wall assembly for use in harsh environmental conditions that utilizes wooden boards that are resistant to marine borers and that have edges that fit together for ease in aligning and connecting the panels in edge-to-edge relationship when being installed and which reduce the likelihood of movement of water and water borne material between the panels.
- It would be desirable to produce structural panels for use in retaining walls and the like that are formed of wood and covered in an air tight plastic envelope with a groove formed at only one edge and no matching tongue at the other edge, with the groove sized and shaped to mate with the rectangular end of the panel.
- Another object of this invention is to provide an improved panel for use in retaining walls and the like that are formed of wood and coated with plastic and have an improved connection feature at its edges that is strong, reliable and inexpensive to form and maintain.
- Another object of this invention is to provide wooden panels covered with plastic and that include a groove formed at one edge that fits the conventional rectangular edge of the adjacent panel with a strong fit and that does not require the presence of a tongue at the edge of the adjacent panel.
- Other objects, features and advantages of the present invention will become apparent upon reading the following specification, when taken in conjunction with the accompanying drawings.
-
FIG. 1 is a perspective view of a section of a retaining wall, showing a vertical pile, a horizontal wale, and a series of panels supported by the wale, with a section of the plastic envelope of the pile removed to illustrate that the core of the pile is formed of wood, and with a portion of the anchor rod removed. -
FIG. 2 is an end cross sectional view of adjacent panels ofFIG. 1 , showing on one side of the figure how the panels are attached to each other, and showing on the other side of the figure the panels expanded from each other to indicate how the panels fit in edge-to-edge relationship. -
FIG. 3 is a side elevational view of adjacent panels showing the last of the panels being moved vertically into position and guided by the lips of the previously positioned panel. -
FIG. 4 is a perspective view of an edge portion of a panel that has been installed in the earth, showing in dash lines how the next adjacent panel will be installed. -
FIG. 5 is a schematic illustration of how the connector lips are formed on the structural panels. -
FIG. 6 is a perspective view of a wall formed with the structural panels of the preceding figures, but with the panels oriented horizontally in the wall structure. - Referring now in more detail to the drawings, in which like numerals indicate like parts throughout the several views,
FIG. 1 illustrates a retaining wall 10 that has been assembled for placement between a body ofwater 11 and aland mass 12, for separating the water from the land. While only a portion of the retaining wall is illustrated, it will be seen that it includes a plurality ofvertical piles 14, horizontally extendingwales 16, and a plurality of elongated, vertically orientedstructural panels 18 placed in edge-to-edge relationship. Thepiles 14 are oriented vertically so that they can be driven downwardly through thewater 11 and into the earth below so that the lower end portions of the piles are embedded in the earth and remain stabilized by the earth. Wales 16 are arranged in end-to-end relationship and extend horizontally between thepiles 14 and theland mass 12. The structural panels are elongated and extend vertically. The structural panels are driven downwardly so that their lower extremities are driven through the water into the earth below. The wales are used as a guide to orient the structural panels as they are being driven and the wales support the panels when the retaining wall structure is completed. - The piles, wales and structural panels preferably are made of wood that is treated with chemicals for reducing the rate of deterioration of the wood due to harsh environmental conditions, and due to marine borers and other insects. Additionally, the piles and wales and panels are coated with plastic, such as polyethylene, polyvinyl chloride, or wood flour composites, by extrusion, spraying, or other application methods. The plastic coatings may cover the entire exterior surface of the work products, including sides, edges and the end surfaces thereof. An example of a method of extruding plastic envelopes about piles, wales and panels is disclosed in co-pending U.S. patent application Ser. No. 10/891,1150.
-
Wale 16 includes awooden core 20 that is covered with the plastic envelope.Pile 14 is wooden, as illustrated at 22 and theplastic envelope 24 is applied to the wooden core. Thepanels 18 arewood boards 40 with plastic coating forming theenvelope 42. - A tie rod 26 extends through the
piles 14, itswale 16, and the adjacentstructural panel 18. Tie rod 26 includes anenlarged head 27 and awasher 28 on the outside surface of the pile to spread the forces applied by the tie rod to the pile.Helical threads 29 are formed on the tie rod at its distal end. Ananchor rod 30 includes helical threads 31 at one end and its other end is connected to an anchor, such as poured concrete 32. Aturnbuckle 34 connects thehelical threads 29 and 31 together, thereby adjustably connecting the anchor 32 by theanchor rod 30,turnbuckle 34, tie rod 26, to thepile 14 of the wall structure 10, thereby stabilizing the wall structure in its upright orientation. -
FIGS. 2-4 show thestructural panels 18. Each structural panel is formed of a wooden board orplank 40 that is optionally treated with chemicals that tend to reduce the rate of deterioration of the boards. Theboards 40 are rectangular in cross-section and are elongated. For example, a typical board used as a structural panel may be from one to four inches in thickness and from four to twelve inches in width. Other dimensions are available, depending on conditions such as the size of the boards needed at the job site, the supply of stock available to the manufacturer of the panels, and the price of the product. The example illustrated inFIG. 2 is a board that is two inches in thickness and eight inches in width, and is rectangular in cross-section and would be of a length as may be desired at the site where it is to be constructed, for example ten feet in length. - The
board 40 of thestructural panel 18 is clad in aplastic envelope 42, with the cladding being in abutment with the surfaces of the board. For example, opposed side surfaces 44 and 45 of the board are covered byside sheets edge sheets plastic envelope 42 will conform in shape to the exterior surfaces of theboard 40, which will be rectangular. The thickness of the plastic may vary, depending upon the type of plastic that is to be used. An example of an acceptable thickness of a polyvinyl chloride envelope is 0.070 inches, with a variance of plus or minus 0.015 inches. - Edge connector means 54 are applied to a
first edge surface 55 of thestructural panel 18, with the opposedsecond edge 56 not requiring edge connector means. As shown inFIG. 2 , the edge connector means 54 includes a pair oflips first edge 55. Thelips strips opposing side sheets longitudinal segment 62 of each strip adhered to theside sheets longitudinal segment 63 protruding on laterally beyond the side sheets to form thelips lips first edge 55 of the structural panel, form aU-shaped recess 65, with the lips being spaced apart a distance substantially equal to the thickness of theboard 40 and the thicknesses of itsside sheets - The
second edge 56 of the structural panel does not have a tongue or groove, but remains with the conventional double right angle edge or “right angle edge.” When the second orright angle edge 56 of astructural panel 18 is placed adjacent thefirst edge 55 of a panel that includes the edge connector means 54, thesecond edge 56 fits snugly within theU-shaped recess 65, and thelips adjacent side sheets plastic envelope 42. Thelips - As shown in
FIGS. 3 and 4 , when a series of panels have been driven into theearth 67 below thewater 11, the new panel 18B will have itssecond edge 56 received in theU-shaped recess 65 formed by thelips arrow 68, so that thelips first edge 55 of the previously installed structural panel guide the new panel 18B as it is being driven downwardly. This tends to guide the panels so that they will be connected together in a straight wall. - After the panels have been installed as indicated in
FIG. 1 , thestrips first edge 55 of each panel overlie the adjacent edges of the adjacent panels, thereby tending to block the passage of water and water-borne materials between the adjacent panels. - Typically, the process of forming the
structural panels 18 involves the cladding of the panels with the plastic envelopes. As stated previously, this can be performed by a vacuum extrusion process described in co-pending U.S. patent application Ser. No. 10/891,930, which is incorporated herein by reference in its entirety. Generally, the process may include vacuum extrusion of the plastic about the boards so that the boards are enveloped by the plastic and the vacuum draws the plastic into direct contact with the boards, thereby substantially eliminating air from between the plastic and the boards. - Once the panels have been clad with plastic, the
strips FIG. 5 shows in schematic form anextruder 70 that includes dieopenings 71 and 72 that are arranged in spaced relationship in accordance with the anticipated thickness of thestructural panel 18 that includes theboard 40 and itsplastic envelope 42 with itsside sheets edge sheets extruder 70 is shaped so that it lays down thestrips first edge 55 of thestructural panel 18. The strips are formed of a material that is compatible with the material of the plastic envelope of the board, such as polyvinyl chloride, and the temperature and consistency of thestrips side sheets strips side sheets edge sheets plastic envelope 42. The over hanging segments of the strips form thelips - While the inventors have disclosed the
strips panels 18, it is anticipated that other connection methods may be used. - With the
strips lips FIG. 3 , as it is being moved downwardly as indicated byarrow 68 into edge abutment with respect to previously installedstructural panel 18A. In addition, thestrips U-shaped recess 65 between the lips of an adjacent panel, form a stable wall structure. - It will be noted that the
structural panels 18 have only one pair ofedge connector lips edge structure 51. The opposingedge structure 50 is free of any reconfiguration and keeps its original rectangular shape with the pair of right angle corners. This reduces the manufacturing expense and reduces the likelihood of error in the manufacturing process. -
FIG. 6 shows anotherwall structure 75 formed of thestructural panels 18. The panels are oriented horizontally, stacked upon one another, with their first edges that have the protruding lips facing vertically and in registration with the rectangular second edge of the adjacent panel. The panels may be formed of equal length and their ends aligned. A series of piers such as upright I-beams 77 are driven into the earth and/or supported by poured concrete 78 in lateral alignment with each other with theiroppositely facing grooves 80 facing the next adjacent I-beams. The structural panels are assembled with their opposed ends 81 received in thegrooves 80 of adjacent I-beams. Other types of piers may be used if desired. - The overlapping
lips panels 18 in a wall structure aligned and tend to minimize effects of lateral displacement of the panels due to warping of the panels or engagement of lateral forces against the panels, both when the panels are oriented vertically or horizontally. - While the
piles 14 andpanels 18 ofFIGS. 1-5 are disclosed as being vertically oriented, and the wales and panels horizontally oriented, and the piles ofFIG. 6 are disclosed as being vertically oriented and the panels horizontally oriented, it will be understood that these and other structural components may not be precisely installed and the terms such as “vertically”, “horizontally” and “upright” are to generally describe the orientation of the components of the wall structure with respect to one another. - Although a preferred embodiment of the invention has been disclosed in detail herein, it will be obvious to those skilled in the art that variations and modifications of the disclosed embodiment can be made without departing from the spirit and scope of the invention as set forth in the following claims.
Claims (23)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/197,973 US20060010819A1 (en) | 2004-07-15 | 2005-08-05 | Retaining wall with plastic coated wooden panels |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/891,930 US7393482B2 (en) | 2004-07-15 | 2004-07-15 | Process for applying sleeve to pole and sleeved pole |
US11/197,973 US20060010819A1 (en) | 2004-07-15 | 2005-08-05 | Retaining wall with plastic coated wooden panels |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/891,930 Continuation-In-Part US7393482B2 (en) | 2004-07-15 | 2004-07-15 | Process for applying sleeve to pole and sleeved pole |
Publications (1)
Publication Number | Publication Date |
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US20060010819A1 true US20060010819A1 (en) | 2006-01-19 |
Family
ID=46322395
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US11/197,973 Abandoned US20060010819A1 (en) | 2004-07-15 | 2005-08-05 | Retaining wall with plastic coated wooden panels |
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US (1) | US20060010819A1 (en) |
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20070092343A1 (en) * | 2005-10-19 | 2007-04-26 | Cargill Kevin W | Micropile Retaining Wall |
US20080127580A1 (en) * | 2004-07-09 | 2008-06-05 | Pierre-Louis Desjoyaux | Device for Producing Above Ground Open or Closed Structures |
US20090202309A1 (en) * | 2008-02-07 | 2009-08-13 | Rabichev Val A | Green Retaining Wall Utilizing Helical Piers |
CN108547313A (en) * | 2018-05-23 | 2018-09-18 | 河海大学 | A kind of curved surface reinforced earth bulkhead panel construction and its assembling method |
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US3869868A (en) * | 1973-12-27 | 1975-03-11 | Eugene Irsai | Retaining wall support device |
US4214412A (en) * | 1978-12-04 | 1980-07-29 | Barylski Gary S | Panel holder and fastener for home, commercial and industrial use |
US4804299A (en) * | 1986-07-09 | 1989-02-14 | United International, Inc. | Retaining wall system |
US5081810A (en) * | 1990-06-11 | 1992-01-21 | Emmert Second Limited Partnership | Building panel |
US5360296A (en) * | 1992-04-23 | 1994-11-01 | Angelette A M | Earth retaining wall |
US5360295A (en) * | 1993-08-26 | 1994-11-01 | Isacksen Jeffrey D | Plastic sheath for wood bulkheads |
US5950389A (en) * | 1996-07-02 | 1999-09-14 | Porter; William H. | Splines for joining panels |
US5984044A (en) * | 1998-07-31 | 1999-11-16 | Christensen; Arthur E. | Acoustical barrier wall with protective sleeves and method of assembly |
US6135675A (en) * | 1997-12-19 | 2000-10-24 | Northstar Vinyl Products Llc | Sheetpile system including full plastic exterior |
US6371699B1 (en) * | 1997-10-16 | 2002-04-16 | Durisol Inc. | Anchored retaining wall system |
US6698157B1 (en) * | 2000-10-31 | 2004-03-02 | William H. Porter | Structural insulated panel building system |
-
2005
- 2005-08-05 US US11/197,973 patent/US20060010819A1/en not_active Abandoned
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US3313073A (en) * | 1962-09-24 | 1967-04-11 | Foam Products Corp | Joint assemblies for insulation panels |
US3869868A (en) * | 1973-12-27 | 1975-03-11 | Eugene Irsai | Retaining wall support device |
US4214412A (en) * | 1978-12-04 | 1980-07-29 | Barylski Gary S | Panel holder and fastener for home, commercial and industrial use |
US4804299A (en) * | 1986-07-09 | 1989-02-14 | United International, Inc. | Retaining wall system |
US5081810A (en) * | 1990-06-11 | 1992-01-21 | Emmert Second Limited Partnership | Building panel |
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US5360295A (en) * | 1993-08-26 | 1994-11-01 | Isacksen Jeffrey D | Plastic sheath for wood bulkheads |
US5950389A (en) * | 1996-07-02 | 1999-09-14 | Porter; William H. | Splines for joining panels |
US6371699B1 (en) * | 1997-10-16 | 2002-04-16 | Durisol Inc. | Anchored retaining wall system |
US6135675A (en) * | 1997-12-19 | 2000-10-24 | Northstar Vinyl Products Llc | Sheetpile system including full plastic exterior |
US5984044A (en) * | 1998-07-31 | 1999-11-16 | Christensen; Arthur E. | Acoustical barrier wall with protective sleeves and method of assembly |
US6698157B1 (en) * | 2000-10-31 | 2004-03-02 | William H. Porter | Structural insulated panel building system |
Cited By (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20080127580A1 (en) * | 2004-07-09 | 2008-06-05 | Pierre-Louis Desjoyaux | Device for Producing Above Ground Open or Closed Structures |
US8266845B2 (en) * | 2004-07-09 | 2012-09-18 | Pierre-Louis Desjoyaux | Device for producing above ground open or closed structures |
US20070092343A1 (en) * | 2005-10-19 | 2007-04-26 | Cargill Kevin W | Micropile Retaining Wall |
US7600948B2 (en) * | 2005-10-19 | 2009-10-13 | Schnable Foundation Company | Micropile retaining wall |
US20090202309A1 (en) * | 2008-02-07 | 2009-08-13 | Rabichev Val A | Green Retaining Wall Utilizing Helical Piers |
US7677840B2 (en) * | 2008-02-07 | 2010-03-16 | Val Rabichev | Green retaining wall utilizing helical piers |
CN108547313A (en) * | 2018-05-23 | 2018-09-18 | 河海大学 | A kind of curved surface reinforced earth bulkhead panel construction and its assembling method |
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