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INTRODUCTION
1.1 GENERAL
Fibre Reinforced Cementitious Composites such as Steel Fibre Reinforced Concrete
(SFRC), Slurry infiltrated fibre composites (SIFCON) are extensively applied in both
civilian as well as strategic sector ever since it was first developed. There is still a lot
of scope for application of fibre reinforced cementitious composites with/without
infills in strategic utilization for protection against multiple hits of short and sharp
projectiles. This can be achieved by improving the ductility and tensile strength of the
composite panels.
In recent years new fibres such as Carbon or Kevlar and low modulus man-made
polypropylene, nylon or natural (Cellulose, Sisal, Jute) fibres have been used in
various structural applications in addition to steel fibre and glass fibre.
Crack controlling ability of fibres is found to be better than reinforcement bars (Bentur
and Mindess 2007). However, since they are short in length and randomly distributed
in cementitious matrix, they may not be able to resist tensile stresses efficiently
compared to conventional reinforcements. This problem can be solved by making sure
that there is closer dispersion of fibres into the matrix.
While conventional reinforcement is used to increase load-bearing capacity of concrete
members, fibre reinforcement is effective in resisting both crack initiation and
propagation. Due to these properties, steel fibre reinforcement has been applied as thin
layers in structural components, tunnel linings, blast and impact resistant structures,
precast piles slabs and pavements etc.
In modern concrete technology, both are prudently applied together to achieve
enhanced strength as well as improved performance. Because short steel fibres
improve the ductility of cementitious composite members there is improved energy
absorption capacity. By virtue of all these mechanical properties, improved impact
resistance as well as fatigue and abrasive resistance of composite panels are possible.
1
CHAPTER 2
LITERATURE REVIEW
Thamilselvi and Manoharan (2008) have reported that SIFCON absorbs 132% more
energy compared to conventional concrete in beam column joints in addition to
reducing congestion of reinforcement.
Teng et al. (2008) have studied the impact behaviour with volume of fibre 1 to 2 % in
the panels of size 500 x 500 x 100 mm. Both numerical and experimental results
reported to correlate well.
Rao et al. (2008) conducted experiments on two way slab for punching shear
resistance and found significant enhancement in punching shear resistance as
compared to fibre reinforced concrete (FRC) and normal reinforced cement concrete
(RCC).
Satioglu (2009) analysed mechanical behaviour of high performance cement based
composite slabs under impact loading. A simplified method for modelling the
behaviour of SIFCON by modifying the tensile strength of concrete was also
suggested.
Yazici et al. (2010) conducted study on effect of steel fibre alignment and high volume
mineral admixture replacement on mechanical behaviour of SIFCON. It was reported
that effect of fibre orientation on fracture energy is considerably higher than that on
flexural strength.
Rao et al. (2010) have conducted impact tests using drop hammer on SIFCON slab of
size 600x600x50 mm for varying volume percentages (8-12%) of steel fibres. It was
found that the energy absorption is much better as compared to FRC and RCC slabs.
Researchers
Year
Material
used
Comp.
Strengt
h MPa
Size of panel,
mm
Velocity,
m/s
Projectile
size
Diameter
(mm)
and nose
shape
Dancygier
and
Yankelevsk
y
199
6
Concret
e
34-110
400x400x4060
85-230
Sharp
nosed/
/2=19.6
5 deg
Luo et al.
200
0
SIFCO
N
Vf=710%
116
400x400x300
;
500x500x300
300-370
Sharp
nosed/
=8.8
deg
Maalej et al.
200
5
HFECC
Vf=0.51.5%
70
300x170x75150
300-700
12.6 mm
dia/ogive
CRH
=2.5
Zhang et al.
200
5
Concret
e
45-235
300x170x
150
620-700
12.6 mm
dia/
ogive
/CRH
=2.5
Zhang et al.
200
7
HSFRC
45-170
300x170x150
610-710
12.6 mm
dia/
ogive
/CRH
=2.5
201
1
SFRCC
vf = 10
%
80MP
a
500
x500x100
300x300x100
800-900
caliber
5.56 mm
and,
7.62 mm
Present
study
Based on existing literature, it can be seen that number of studies have been reported
on cementitious composite panels made of reinforced concrete, FRC, SIFCON etc.
however clear information is not found from reported literature on the design aspect of
these panel.
It is observed that experimental and computational work done related to short fibre
reinforced cementitious composite panels is still limited as compared to plain or
reinforced concrete studies. Hence, there exists a need to improve the understanding
on the impact behavior of such SFRCC engineered panels both experimentally as well
as computationally.
In this report, characteristics of fibre reinforced cementitious composite such as SFRC,
SIFCON are presented in detail. The present study focuses on the development of fibre
reinforced cementitious composite panels which provide the aesthetic look as well as
protection against short and sharp nosed projectiles.
Details of the study conducted using two different most commonly used caliber
diameters namely 5.56 mm and 7.62 mm projectiles are given in this report. The main
advantage of the developed cementitious composite panels is that they are relatively
cheaper than metal covers and do not allow fragmentation and ricochet of projectile.
CHAPTER 3
METHODOLOGY
3.1 FIBRE REINFORCED CEMENTITIOUS COMPOSITES
3.1.1 STEEL FIBRE REINFORCED CONCRETE:
Steel fibre reinforced concrete (SFRC) can, in general, produced using conventional
concrete practice, though there are obviously some important differences. The current
technology for mixing, placing and finishing SFRC is described in detail in code ACI
544.3R, which emphasizes these differences. ASTM C 1116 also provides valuable
information on the methods of specifying and manufacturing SFRC.
3.1.2 DISPERSION OF FIBRES IN CONCRETE MATRIX:
The basic problem is to introduce a sufficient volume of uniformly dispersed fibres to
achieve the desired improvements in mechanical behaviour, while retaining sufficient
workability in the fresh mix to permit proper mixing, placing and finishing. The
performance of the hardened concrete is enhanced more by fibres with a higher aspect
ratio, since this improves the fibrematrix bond.
On the other hand, a high aspect ratio adversely affects the workability of the fresh
mix. In general, the problems of both workability and uniform distribution increase
with increasing fibre length and volume. It was these contradictory requirements that
led to the development of the deformed fibres that are currently in use, with which
bonding is achieved largely through mechanical anchoring, which is much more
efficient than the frictional shear bond stress mechanism associated with straight
fibres.
For instance, Mangat and Azari have shown that the apparent coefficient of friction is
about 0.09 for hooked end fibres, compared with only about 0.04 for straight fibres.
Nonetheless, even with modern deformed fibres in the practical range of lengths
(1260 mm), and with modern superplasticizers, only up to about 2% of fibres can be
incorporated using conventional concrete practice.
When steel fibres are introduced into a concrete mix, they generally have a detrimental
effect on the packing density of the aggregates; this effect limits the maximum fibre
contents. For plain concretes, the maximum packing density is obtained with about a
40% volume of fine aggregate.
For low fibre content mixes (< about 0.5%), it is not really necessary to change the
concrete mixture design from that used for plain concrete. However, for higher fibre
volumes, the maximum packing density can be achieved only with a higher fines
content. For instance, for 2% fibres, about a 60% fines content is required to achieve
the maximum packing density. Different fibres have different geometries, and
therefore different packing densities of their own.
It should be noted that it is not really practical or possible to use the highest fibre
contents (approaching 10%) since the fibres would interlock during mixing (Fig. 1).
One of the chief difficulties in obtaining a uniform fibre distribution is the tendency
for steel fibres to ball or clump together.
Clumping may be caused by a number of factors:
The fibres may already be clumped together before they are added to the mix;
normal mixing action will not break these clumps down.
Fibres may be added too quickly to allow them to disperse in the mixer.
The mixer itself may be too worn or inefficient to disperse the fibres.
Introducing the fibres to the mixer before the other ingredients will cause them
to clump together.
Fig 1 Fines content vs.fines content for determination of optimum packing density
(Harex fibres, 32 mm long, 0.9 mm diameter), from Hoy and Bartos [source- Naaman,
1992]
7
PW Ccrit=75
SGf d
K
SGc l
where,
PWccrit is the critical percentage of fibres (by weight of mix);
SGf , the specific gravity of fibres;
SGc, the specific gravity of concrete matrix;
d/l, the inverse of fibre aspect ratio;
K, the Wm/(Wm + Wa) and
Wm, is the weight of mortar fraction (particle size < 5 mm);
Wa, the weight of aggregate fraction (particle size > 5 mm).
(1)
They recommended that, to permit proper compaction, the fibre content should not
exceed 0.75 PWccrit . The second factor which has a major effect on workability is the
aspect ratio (l/d) of the fibres. The workability decreases with increasing aspect ratio.
In practice, it is very difficult to achieve a uniform mix if the aspect ratio is greater
than about 100.
In general, to provide better workability, SFRC mixes contain higher cement contents
and higher ratios of fine to coarse aggregate than do ordinary concretes. Thus, the mix
design procedures that apply to conventional concrete may not be entirely applicable
to SFRC.
Commonly, both to improve workability and to reduce the quantity of cement, up to
35% of the cement may be replaced with fly ash. In addition, to improve the
workability of high fibre volume mixes, water reducing admixtures and, in particular,
super-plasticizers are often used.
3.1.4 SLIP HARDENING FIBRE:
Engineering of the fibre and the interface to obtain a slip hardening behaviour of the
fibre during pull-out is an additional means that has been studied and used to obtain
composites of enhanced performance. Changing the shape of the fibre is almost a
routine means taken to improve the bond in general, and to obtain a strain hardening
pull-out in particular.
This is achieved by inducing mechanical bonding (anchoring) into the system, as is
often done by changing the geometry of the fibre (e.g. hooks, crimps). Some of fibre
types are shown in Fig. 2.
When the geometry is properly adjusted, slip hardening behaviour can be obtained.
More advanced means have been recently suggested to enhance this response in the
fibres, by formation of more complex shapes, which are not linear in nature, but rather
2D and 3D dimensional.
Naaman developed the concept of twisting polygonal fibres, and optimizing this effect
by using geometries which before twisting, have a shape which is intrinsically of a
higher surface area. He defined a parameter of fibre intrinsic efficiency ratio (FIER)
which is the ratio of the bonded lateral surface area of the fibre, to its cross-section
area.
The ratio can be calculated per unit length or total length as given by Eqn. (2):
FIER=l/ A
where,
(2)
is the perimeter;
l, the length of fibre and
A, the cross-section area of fibre.
Fig. 2 Shapes of fibres and the relative FIER values (after Naaman).
A different type of mechanical bonding was obtained by using clip and circular type
geometries. The fibre pull-out resistance could be maximized by optimizing the radius
of curvature at the edges of the clip to the length. The latter provides the mechanical
anchoring characteristics. The performance of such a fibre was shown to be better than
10
12
Fig. 3 Structure of fabrics: (a) weft insertion knit, (b) short weft knit and
(c) woven (plain weave (after Peled and Bentur [28])).
An example of a fabric where the warp and weft yarns are linked by stitches is
presented in Fig. 4. The geometry in 3D can assume many different complex shapes,
depending on the objective of the reinforcement.
The fiber volume depends on the fiber type and the vibration effort needed for proper
compaction. Smaller or shorter fibers may pack denser than longer fibers and higher
fiber volumes can be achieved with careful and sufficient vibration (Lankard 1984).
3.3.1 FIBRE ALIGNMENT:
Fiber alignment also greatly affects the behavior of a SIFCON product as depicted in
Fig. 5. Fibers can be aligned parallel or perpendicular to the loading direction or can
be placed randomly into the mold. The ultimate strength, residual strength, ductility,
and energy absorption properties are all affected by the fiber alignment (Naaman et al.
1987; Stiel et al. 2004).
This behavior is quite different from conventional fiber-reinforced concrete. In the
case of oriented fiber placement, two different loading types were applied in uniaxial
compressive test; loading parallel to the fibers and perpendicular to the fibers.
Contrary to flexural strength and fracture energy, compressive strength of the oriented
SIFCON composites decreased in some cases (control and 50% FA incorporated
series) compared to the compressive strength of slurries itself (without fibers).
Fig. 6 shows the influence of fibre orientation on the material properties.
15
16
CHAPTER 4
CONSTRUCTION TECHNIQUES
4.1 SIFCON CONSTRUCTION TECHNIQUES:
There are five basic elements need to consider when fabricating SIFCON specimens:
(1) Formwork, (2) Fiber Placement, (3) Slurry placement (4) Finishing and (5) Curing
The selection of the fiber type and the slurry mix design are considered to be functions
of the design process.
4.1.1 FORMWORK:
The formwork for SIFCON is similar to that for conventional concrete. Both steel and
wood forms have been successfully used in the past. The design of the form follows
the same procedures for concrete using the hydrostatic pressure from the slurry.
The formwork design procedures developed by the American Concrete Institute (ACI)
attempt to consider the fact that concrete attains some internal strength due to the
bridging effect of the aggregate in the concrete and the result of the initial setting of
the cement during the time of placement.
Therefore, the pressure distribution on the form work is not necessarily hydrostatic
from top to bottom, but is limited to a maximum pressure dependent on the rate of
placement, temperature and consolidation Techniques.
17
or in a fluid state, for a relatively long time. This is necessary to allow the slurry to
flow through and fully infiltrate the fiber bed.
In addition, most typical structural components are relatively short, say, 3 M or less in
height, and could probably be filled in less time than needed for the slurry to begin its
initial set.
Formwork for walls or columns should be designed for the use of external form
vibration. This is especially necessary if the slurry is designed to be poured into the
fibers from the top of the form. Generally, small pneumatic vibrators of the type used
on bulk cement hoppers, spaced about 6 ft on centers on one side of the form, have
been shown to be adequate for walls up to 8 in thick.
For thicker walls, small vibrators on both sides of the wall or larger external form
vibrators could be used. As for concrete construction, all exposed comers on SIFCON
components should be chamfered 0.5 to 0.75 in. Fabricating thin ribs, extensions, or
acute comers, which must remain undamaged during the removal of the forms, is
generally more successful with SIFCON than with conventional concrete.
However, care should be taken to provide reasonable chamfers at sharp corners.
Formwork for rustication grooves, insets and block outs should be provided with
adequate draft to facilitate removal of the forms. For components requiring step backs
or ledges, the formwork should be designed to permit complete fiber placement under
the formwork.
In general, the horizontal part of the form should be designed to be installed after the
fiber has been placed. Small holes in the horizontal form work should be provided to
allow any air trapped under the ledge to escape as the slurry rises in the form.
After the slurry reaches the level of the holes and begins to flow out, the holes can be
sealed with plugs or screws. The use of architectural form liners can also be used with
SIFCON.
Embedded items such as threaded inserts, plates, and pipe sleeves can be installed in
SIFCON formwork using the same techniques as for conventional concrete. Care
should be taken to ensure that any fasteners penetrating the form to support the
embedded items are adequately sealed to prevent leakage of the slurry.
19
employed or economically adapted for placing the steel fiber in SIFCON. In general,
all the fiber placement equipment reviewed and observed can be classified as having
two basic part.
The first part is a system that takes the mass of interlocked fibers as it comes
packaged from the manufacturer and separates it into single individual fibers. The
second part is a transportation system that moves the fiber from the first system to a
location where it can fall freely into the form.
4.1.3 ROTATING DRUM:
The rotating-drum system consists of a cylindrical or slightly conical steel drum (Fig.
8). The drum is mounted with its longitudinal axis ranging from about 45 deg to nearly
horizontal. A circular steel plate is mounted at the lower end of the drum. A gap,
ranging from 10 to 30 mm (0.375 to 1.25 in) in width, is provided between the edge of
the plate and the wall of the drum.
21
The fibers fall onto a transport system such as a conveyor belt or vibrating tray where
they are carried to the form. The system could be used to place fibers for thin SIFCON
slabs or pavements without a transportation system by moving the entire drum system
back and forth over the area until the correct thickness of fiber is achieved.
Figure 9 shows steel rods or studs on the rotating end plate break up the fiber mass
into individual fibers which fall out between the plate and the drum wall as before.
Examples of each of the two versions are in operation today for adding fiber to a
conventional concrete mix being prepared in a standard transit-mix truck.
Both systems are relatively simple in design and are probably fairly inexpensive to
fabricate. In addition, they are probably inexpensive to operate since operation
requires only one or two semiskilled or unskilled laborers.
Because the systems observed are designed for use in making conventional fiberreinforced concrete with a fiber volume density of 2 percent or less, their maximum
fiber-output rate is about 20to 30 kg/min.
Redesigning the system by increasing the diameter of the drum, the geometry of the
steel rods and/or the speed of rotation may help to increase the fiber-output rate.
Fig. 9 Steel rods or studs on the rotating end plate [Schneider and Mondragon
(1989)
4.1.4 VIBRATING SCREEN SYSTEM:
22
The vibrating screen system consists of a circular or rectangular steel hopper. Inside
the hopper are one or more levels of screens. The openings in each successive layer of
screens vary from large to small with the largest openings in the uppermost screen
(Fig. 10).
In operation, a mass of fibers, as it comes from the manufacturer, is dumped into the
top of the hopper, where it comes to rest on the top screen. The hopper system is then
rapidly shaken or vibrated.
This vibration causes smaller clumps of fibers to fall through the upper screen onto the
lower one. Smaller and smaller clumps of fiber continue to fall through the openings in
the successively lower screens until only individual fibers fall from the last screen.
The individual fibers fall out of the bottom of the hopper onto a transportation system
such as a conveyor belt or vibrating tray which carries them to the form. Vibrating
screens and trays are common in the manufacturing industry today.
For example, a system similar to the one described above is used to separate and
package nails and bolts. Discussions with manufacturers of vibratory equipment
indicate that almost any type of system can be designed and built to meet the needs of
the user. The hopper system described is simple to fabricate and operate, requiring
only off-the-shelf equipment. As with the rotating drum system, the vibrating system
can be operated with only one or two unskilled laborers.
Fig. 12 Pumping slurry from bottom to top [Schneider and Mondragon (1989)]
4.1.6 CURING:
The curing procedures for SIFCON are the same as for conventional concrete.
Depending on the application, water spray or fogging, wet burlap, waterproof paper,
plastic sheeting or liquid membrane compounds can be used. Probably the most
practical and economical are the liquid membrane compounds. They are well
developed and in common use throughout the concrete industry.
4.1.7 MAINTENANCE:
25
Because of the relative newness of SIFCON, little is known about the long-term
effects of weather on the material. There is some evidence that tends to indicate that
SIFCON is highly resistant to deterioration from the weather.
Vertical Surfaces: For a formed vertical surface exposed to the elements such as a
wall or a column, some staining and rusting of those fibers exposed on the surface is to
be expected. A coating of standard concrete sealer should be applied to the exterior
surface to minimize the rusting and streaking.
Horizontal Surfaces: For horizontal surfaces exposed to the elements, an aggregate
topping should be used to cover the fibers near the surface. In addition, an application
of a standard penetrating concrete sealer should be used. If the surface is expected to
be exposed to a harsh environment, including some chemical solutions, a special slurry
mix incorporating latex modifiers should be considered.
4.2 BEHAVIOR OF TENSION AND COMPRESSION:
The tensile strength of SIFCON can exceed 20 MPa, compared to the plain matrix of 7
MPa. Tension tests consisted of uniaxial tensile tests on dog bone-shaped prism
specimens as shown in Fig. 13.
The fibers were manually distributed into the molds and oriented as much as
practicable in a direction parallel to the loading axis of the test specimens. The molds
were placed on vibrating tables and subjected to vibration during fiber placement to
obtain compaction of fibers. Alignment was more effective in the narrow testing region
of the molds.
26
27
Fig. 14 Flexural strengths versus fiber contents (Balaguru and Kendzulak, 1986)
The study on variation in flexure tests shown in Fig. 14 based on mix design and fibre
content finally leads to the following observations:
a) The flexural strength of SIFCON is an order of magnitude greater than the
flexural strength of normal fiber-reinforced concrete.
b) For a constant fiber length, the flexural strength increases with the volume
fraction of fiber only up to a certain limit. After certain fiber content, the bond
strength decreases because of the lack of matrix in between the fibers, thus
reducing the flexural strength. The optimum fiber content reported to be in the
range of 8 % to 10 %, as shown in Table 2.
c) The optimum fiber volume seems to decrease with an increase in fiber length.
For the same fiber volume, longer fibers provide a slight increase in flexural
strength.
Table 2 Flexural strength of SIFCON (Balaguru and Kendzulak, 1986)
Fiber size
L/D (mm)
30/0.5
40/0.5
50/0.5
60/0.5
% of fiber volume
6
8
10
12
4
6
8
10
4
5
6
8
5
6
8
10
28
Flexural strength
(MPa)
55.2
61.8
91.9
62.7
46.9
67.7
75.4
76.5
36.5
58.8
78.6
73.7
49.6
53.7
72.1
63.4
Based on the test results conducted in those studies, the following conclusions were
drawn:
a) SIFCON led to a significant increase in the bond strength of deformed
reinforcing steel bars. Average bond stresses ranging from 14 to 28 MPa were
observed. This range was between 2 and 4 times that of bars embedded in plain
concrete.
b) The initial bond stiffness was at least 5 times higher than that observed for plain
concrete.
c) Pullout work, or dissipated bond energy, was over 20 times greater than that for
plain concrete.
d) Reinforcing bars embedded in SIFCON can resist slip up to 10 times more than
when embedded in plain concrete and still maintain the peak load.
4.6 IMPACT RESISTANCE:
Various aspects of cementitious composites have been investigated by researchers
across the globe in the past two decades. In the 1980s, a new construction technique
was developed to increase the volume content of steel fibres. This has led to the
development of slurry-infiltrated fibre reinforced concrete (SIFCON), in which fibre
volume could range from 4 to even 20%.
Naaman (1989), studied the tensile stress-strain properties of SIFCON. He reported
that, in addition to improved ductility, the tensile strength of SIFCON specimens could
go up to 15 to 20% of their compressive strength in contrast to 5 to 10% realized in
normal concrete.
Plain concrete is one of the conventional materials extensively used in the design of
impact resistant structures. Number of experimental and computational studies has
been reported regarding structural behaviour of the RCC members subjected to quasi30
static and dynamic loadings (including impact and blast). Concrete has advantages
such as economy, higher compressive strength compared to primitive construction
materials, and resistance to heat-temperature rise.
Unfortunately it also has disadvantages such as being semi-brittle and weak in
tension. With the advancement in construction technology, the cure for these
weaknesses has been found by the use of reinforcement steel in concrete.
Under extreme loadings due to impact and blast etc, it was realized that, effect of
these reinforcement bars are quite local instead of global. Therefore, it is understood
that for impact resistance different material characteristics are essential at different
phases of the entire impact process.
4.7 SHORT FIBRE VERSUS WELDED WIRE MESH:
There has been a long-standing controversy regarding the relative effectiveness of
fibres and welded wire mesh in slabs, with the producers and proponents of each type
of reinforcement arguing that theirs is better than the other Zollo and Hays (1991),
Trottier, et al. (2002).
The prime function of the welded wire mesh is to hold the concrete together once it
has started to crack, and a properly designed FRC mix will also serve this function. In
fact, there appears to be little difference between SFRC slabs and welded wire mesh
reinforced slabs, in terms of strength, failure mode, crack initiation and propagation,
and load vs. deflection behaviour [Roberts-Wollmann et al. (2004)].
The caveat is that the welded wire mesh must be correctly placed, at or slightly above
the mid-height of the slab, and this is often difficult to achieve in practice.On the other
hand, Sorelli et al. (2004) found that the crack patterns did differ between the two
types of reinforcement.
The SFRC slab showed the same crack pattern as the plain concrete, while the welded
wire mesh slab led to narrower and more diffuse crackings that developed in the radial
direction. They also found that SFRC slabs were less effective for loads applied at a
corner or an edge.
31
Trottier et al. (2002) reported that properly placed welded wire mesh outerforms
synthetic fibres in these respects because the latter have a lower modulus of elasticity
than the steel or the concrete.
CHAPTER 5
CONCLUSION
It is well known fact from various study on different approaches it is concluded that
SIFCON offers better tensile strength as well as ductility because of its enhanced
toughness due to inclusion of steel fibres.
Due to enhanced tensile strength of SIFCON, the cracks get arrested and they do not
propagate further. This keeps structural integrity of composite panels intact and hence
can sustain loads in post peak region without sudden fracture (like in concrete
members).
Fibres do impart other properties to the concrete, in particular a reduction in plastic
shrinkage cracking. However, compared with both steel and synthetic fibres, welded
wire mesh has been reported by Voigt, et al. (2004) to reduce the maximum crack
width, even though the age at which cracking first appeared was not prolonged.
Thus, when choosing between fibres and welded wire mesh, it is necessary to define
carefully the performance that is most important in a particular application.
Indeed, for some applications like shock resistance panels, it is observed that a
combination of short fibres and welded wire mesh reinforcement will provide the best
solution.
32
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