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Atmospheric behaviour of rolled zinc in eight Canadian atmospheres:
summary of ten years' results
NATIONAL RESEARCH COUNCIL CANADA
DIVISION OF BUILDING RESEARCH
ATMOSPHERIC BEHAVIOUR OF ROLLED ZINC IN EIGHT CANADIAN ATMOSPHERES
--SUMMAR Y OF TEN YEARS! RESULTS by
H. Guttman and C. A. Hamer
Cominco Limited, Sheridan Park, Ontario and
E. V. Gibbons
Division of Building Research,
National Research Council, Ottawa, Ontario
ANALYZED
A joint report of Cominco Limited and the Division of Building Research,
National Research Council.
Internal Report No. 334 of the
Division of Building Research
OTTAWA November 1966
Information is frequently required on the atmospheric corrosion behaviour of different architectural metals at
various locations across Canada. To assist in overcoming
the lack of published information on this subj ect the form er Associate Committee on Corrosion Research and Prevention (A. C. C. R. P.) of the National Research Council, initiated
a metals exposure program. It was a cooperative undertaking
involving Canadian metal suppliers, users and research
organizations. The first metals were selected in 1953 for
exposure at eight outdoor sites across Canada.
The program included, in addition to the architectural metals, a number of different metal and organic coatings
on steel. This report describes the lO-year performance
of rolled zinc panels. Reports have been issued that describe
the performance of thr ee aluminum alloys and aluminum rivetted bimetallic couples, three stainless steels and
two magnesium alloys. A report covering the behaviour
of three steel alloys will be issued in the near future. The specimens of rolled zinc were furnished by Cominco Limited, Sheridan Park, Ontario, which was also responsible for assessing their performance and
in compiling this report. This part of the study was under
the dir ection of Mr. H. Guttman with the assistance of
Mr. C. A. Harner. The arrangements for exposure and
examination of specimens and SOme over-all co-ordination of the program was carried out under the direction of Mr. E. V. Gibbons of the Division of Building Research.
The Division is indebted not only to the companies who have cooperated in making this study possible, but also to those who have contributed to the provision and servicing of certain of the exposure sites.
Ottawa
November 1966
N. B. Hutcheon. Assistant Director
ATMOSPHERIC BEHAVIOUR OF ROLLED ZINC IN EIGHT CANADIAN ATMOSPHERES
--SUMMARY OF TEN YEARS' RESULTS
by
H. Guttman and C. A. Hamer
Cominco Limited, Sheridan Park, Ontario
and
E. V. Gibbons
Division of Building Research,
National Research Council, Ottawa, Ontario
An outdoor architectural metals exposure program was undertaken by the Associate Committee on Corrosion Research and Prevention to obtain information on their relative atmospheric corrosion behaviour at various
locations across Canada. Details of the program were
planned by Subcommittee IIC" of the Associate Committee, and the exposure of the metals selected was carried out at the outdoor test sites of the Division of Building Research
of the National Research Council. The first group of metals
exposed included specimens of rolled zinc, aluminum and aluminum coupled to copper, zinc and mild steel, thr ee low alloy steels, three stainless steels and two magnesium alloys. This report describes the ten-year performance of the rolled
zinc furnished by Cominco Limited. The other materials
for this part of the program were furnished by the Aluminium Lab'oratories Limited, the Steel Company of Canada Limited, Atlas Steels Company and Dominion Magnesium Limited,
respectively. More recently, specimens of copper, muntz
metals, lead alloys, and monel have been added, as well as a number of different metal and organic coatings applied to steel.
The sp e c irn en s for exposure were 4 by 6 in. in size
and of various thicknesses. They were mounted on racks
fitted with porcelain insulator s to hold them in place at 30 deg
to the horizontal facing south. Normally, twelve specimens
of each type of metal were set out initially at each site. This number enabled three specimens of each type to be removed after exposure periods of one, two, five and ten
years. After identification by a punched-hole system and
weighing, the specimens were shipped by the supplier to the National Research Council for distribution to the sites. After each exposur e period it was usual to photograph
the topside and under side of a specimen typical of each lot
before returning the specimens to the original supplier for cleaning, re-weighing and assessment.
The A. C. C. R. P. was disbanded in 1960, but the test
program was continued by the Division of Building Research.
Progress reports have been prepared by Comin co after the
one-, two- and five-year periods, which describe the
performance of the rolled zinc up to this time (1).
These were is sued in 1958 and 1960 and circulated.
DESCRIPTION OF MATERIAL
The rolled zinc specimens that were exposed measured
4 by 6 by O. lOin. They had the following composition,
per cent by weight: Pb 0.08 Cd 0.002 Cu 0.001 Fe 0.004 and were designated B -8 in the series for identification purposes. DESCRIPTION OF TEST SITES
A complete description of the test sites has been published (2). The following is a brief summary of them along with their site number.
1. Ottawa - This site is located on the easterly city limits
and can be classified as semi-rural.
2. Saskatoon - This is a rural site located on the campus
of the Univer sity of Saskatchewan on the outskirts of Saskatoon.
- 3
3. Montreal - This is an industrial site located on
the roof of a two-storey building of the Canadian National Railways in the Point St. Charles district.
4. Halifax - This is a marine industrial site located
on the roof of a Federal Public building in downtown Halifax, two city blocks from the harbour.
5. York Redoubt - This is a rural marine site located
on the Atlantic coast, seven miles from Halifax.
It is at an elevation of 100 ft about 300 ft from
the ocean.
6. Norman Wells - This is a far northern site located
in the Mackenzie River valley about 90 miles south of the Arctic Circle.
7. Esquimalt (Rocky Point) - This is a marine site
on the west coast at the southeast extremity of Vancouver Island, about 15 miles from the city
of Victoria. It is at an elevation of 50 ft and
about 1500 ft from the ocean.
8. Trail - This is a semi-rural site located at
Birchbank in the Columbia River Valley about 6 miles north of the City of Trail.
All of the sites ar e near weather stations of the Meteorological
Division of the Department of Transport. In addition to these
records being available to assist with the interpretation of the exposure results, the relative level of sulphur dioxide at the sites has been measured using the lead peroxide
instrument. This method does not measure the volumetric
concentration of S02 in the atmosphere directly, but presents an integrated measure of the sulphur dioxide "activity" during
a period of exposure. The measurements were made on
a monthly basis. The results have been condensed and
the average level during the ten-year exposure of the
rolled zinc is given in Table I. A graphical representation
of the average concentration of sulphur dioxide during
EXPERIMENT AL PROCEDURE
After the completion of each exposure period the specimens were recalled by NRC, checked, photographed
and then forwarded to Cominco. The specimens were examined
visually, then cleaned of corrosion product, and weight losses and penetration rates were determined. Most of the cleaning of the differ ent lots was carried out using ammonium chloride solution. Its composition and the cleaning procedure are given in Appendix A. The only exceptions to the use of this solution wer e with certain of the lot 3 specimens from sites Nos. 4, 5, 6, 7 and 8, when the suitability of a mixture of chromic acid, silver chromate and strontium chromate and an ammoniacal ammonium acetate solution was investigated. The latter solution was used on the site 4 panels for initial cleaning to r ernove
the excessive foreign deposits present. Sub s equent cleaning cycles on these panels were carried out in the ammonium chloride solution. The chromate solution was used on the specimen 3 panels from sites Nos. 5, 6, 7 and 8 mainly to indicate the suitability of this cleaning agent, particularly in cases where the building of foreign dep os it s on the panels was negligible.
EXPERIMENT AL RESULTS
The appearance of the three specimens of lots one and two from each site was very similar and different from the panels from the other sites. The colour and pattern of the corrosion products and for eign deposits were unique for each site varying from the still shiny, almost uncorroded panels from Norman Wells (site No.6) to the black sooty panels from Halifax (site No.4). The colour transpar encies taken after each exposure period indicated that, in general, this
remained so throughout the ten-year period. Examination
of the panels after cleaning indicated that corrosion was substantially uniform. Minor signs of pitting only in the areas adjacent to the supporting insulators on the more heavily corroded panels were observed after five years of exposur e. After ten year s , pitting had only occurr ed at the more corrosive sites. Corrosion appeared to be more severe on the topside faces than on the underside at all sites.
- 5
The average penetration rates calculated from the corrected weight losses of three specimens per site are
summarized in Table II. The weights, weight losses,
cleaning corrections, corrected losses and penetration rates for the individual specimens from each lot and site
are given in Appendix B. As indicated in Table I I, there
is a large spread in the penetration rates from site to site. At Halifax, which is the most corrosive site, the penetration
rate is more than 100 times that at the least corrosive site,
Norman Wells. The S02 content of the atmosphere appears
to be a critical factor affecting the corrosion of zinc. The
ranking of the sites in severity of corrosion is in the same general order as the S02 level given in Table I. with two
exceptions - - York Redoubt and Es qui.ma.It,
When the five-year results were compiled. in an effort to obtain a clear er under standing of the significanc e of the corrosion rate changes indicated in Table I I, the penetration rate data for all panels exposed during the three exposure periods were analysed by the Cominco
Statistics Group. The findings show that the decreases
in the rates are true decreases at sites Nos. 2, 4, 5, 6
and 7. At site No.8 the differences between panels
within groups were so great that the rate decrease noted
is considered to be due to chance alone. The findings
also show that the rate increases at sites Nos. 1 and 3
are true increases. The corrosion rate decrease at
site No.4 is probably due to the protective action of the relatively heavy foreign deposit that built up on the panels and a decr ease in the S02 content of the
atmosphere during the test period at the site. At
sites Nos. 2, 5, 6 and 7 the corrosion rate decrease
is probably due to the pretective action of corrosion
products formed which remained in situ. The increases
at sites Nos. 1 and 3 could be caused by an increase in the aggressiveness of the atmosphere in question and/or the fact that the panels may be subjected to greater
amounts of precipitation than at the other sites. This
would tend to wash away corrosion products formed. thus making their protective action less effective. A study of the meteorological data does indicate that annual precipitation at Ottawa and Montreal is greater than at all other sites except the two at Halifax.
Figures 2 and 3 show graphs of panel weight loss with
exposure time for each site. For all practical purposes.
these are straight lines indicating that there is little build-up of protective films of corrosion product on zinc panels.
Site No. 4 is the exception; here the corrosion rate was relatively high for the first few years and then decreased
to a fairly constant level. The bar graphs of Figures 4 and 5
also show how these corrosion rates change with time. CONCLUSIONS
1. The Halifax site was by far the most aggressive
atmosphere in the performance of the rolled zinc.
2. Some pitting occurs at the more corrosive sites.
3. The rate of corrosion decreased with time at
all of the sites except Montreal and Ottawa. At these two
sites there was a slight increase in the rate which became fairly constant at Montreal after ten years of exposure.
4. Corrosion appeared to be more severe on the
topside faces than on the under side at all sites.
5. The chromate cleaning method is well suited
for cleaning specimens that are free of a foreign deposit build-up.
REFERENCES
1. The corrosion behaviour of major architectural
and structural metals in Canada: Summary of two year
results. National Research Council, Ottawa, Associate
Committee on Corrosion Research and Prevention. 24 February 1959.
2. Gibbons, E. V. Outdoor exposure sites of the
National Research Council. Chemistry in Canada,
Vol. 12, No.3, March 1960, p. 44-48, (NRC 5593).
TABLE I
AVERAGE AMOUNT OF SU LPHUR DIOXIDE
IN THE ATMOSPHERE AT E;ACH SITE FROM 1955-1965 2
Site No. Location Mg of S03/dm /day
1. Ottawa 0.52 2. Saskatoon O.13
3.
Montreal 1. 614.
Halifax 5. 13 5. York Redoubt 0.25 6. Norman Wells 0.01 7. Esquimalt 0.06 8. Trail 0.72AVERAGE PENETRATION RATES - rn , p. y.
Exposure Site 1 year 2 years' 5 years' 10 yearSl
exposure exposure exposure exposure
1- Ottawa 0.045 0.047* 0.050 0.055 2. Saskatoon 0.025 0.017 0.015 0.011 3. Montr ea.l 0.110 O. 114 O. 131 0.130 4. Halifax 0.916 0.851 0.716 0.532 5. York Redoubt 0.076 0.067 0.055 0.055 6. Norman Wells 0.014 0.009 0.005 0.005 7. Esquimalt 0.027 0.020 0.019 0.017 8. Trail 0.082 0.078 0.074 0.074
5.0
>-<
4.0
0 -toe :E 0 0" Vl u.. 0 c.:> :E3.0
0 0 :::I: I -L&.J セ:E L&.J 0 X 0 0:::2.0
LIJ 0-0<
LIJ - I - I LIJ>
LIJ - I IN1.0
0 Vlo
- ,....-r- -r- -r- --f-- -I - -- I X <L&.J I-- <u.. 0::: I--
Z - I < 0 :::I: セ ,..-'-- I -- I co f-- '-
< :::J -<==
0 Vl 0::: 0 - I I - < LIJ Z - I I -0::: 0 LIJ-
l - I-==
0 0 - I セ I - <-
,..- 0::: < セz
-0 セ-
«
>-
Vl :::J セn
< 0 0::: Vl Vl 0 r-J .--LIJ Z4
3 8 1 5 SITENO.2
7
6
FIGURE 1AVERAGE AMOUNT OF SULPHUR DIOXI DE IN THE ATMOSPHERE AT'EACH SITE 1955-1965
10
9
8
7
6
5
4
3
2
1
o
7
CD
Ottawa
®
Saskatoon
- JCD
Montreal
LLJz
6
®
c(York Redoubt
c,-
®
Norman Wells
:E セ5
(f)
-
Esquimalt
V't®
V'tTra i I
0 - J4
I -:::I: セ LLJ3
:i=
LLJ セ c( a::::2
LLJ>
c(1
EXPOSURE TIME, YR
FI GURE
2
WEIGHT LOSS VS TIME EXPOSED FOR ROLLED ZINC
EXPOSED AT TEST SITES INDICATED
35
セ30
LI.I Z«
0--
:E
25
<.:> -Vl Vl20
0 セ I -:I: <.:>15
LI.I3:
LI.I <.:>10
/
«
0::: LI.I>
«
5
•
1
2
3
4
5
6
7
EXPOSURE TIME, YR
8
9
10
FIGURE 3
WEIGHT LOSS VS TIME EXPOSED FOR ROLLED ZINC
EXPOSED AT HALIFAX
./1.OTTAWA
0.4
ESQUIMALT
->=
.
0.2
-a...
:E--
0
I tI\ LI.I....
<. c:::z
0.6
0tI\
SASKATOON
NORMAN
0 c:::
WELLS
c:::8
0.4
I---
セ-0.2
セ-o
r-
I-1
2 5 10
1 2 5 10
YEARS OF EXPOSURE
FI GURE
4
ATMOSPHERIC CORROSION RATE OF ROLLED
ZINC EXPOSED FOR 1, 2, 5 AND 10 YEARS
AT OTTAWA, ESQUIMALT, SASKATOON AND
3172-4-1.0
0.8
0.6
· 0.4
>-·
a.·
:E• 0.2
Vl UJ to-<C e::::z
0
o
HALIFAX
P--"" セ セ -セ I-- I -I-- -,----MONTREAL
-Vlo
e:::: e::::o
0.6 , . . - - - .
uTRAIL
0.4
0.2
YORK
REDOUBT
1 2 5 10
1 2 5 10
YEARS OF EXPOSURE
FI GURE
5
ATMOSPHERIC CORROSION RATE OF ROLLED
ZINC EXPOSED FOR 1, 2, 5 AND 10 YEARS
AT HALIFAX, MONTREAL, TRAIL AND YORK
Cleaning Rrocedure
1. Scrub with water and detergent using a soft bristle brush to r ernov e loose corrosion products.
2, Immerse in well-stirred, 10% NH
4Cl solution at 60°F for 5 min.
3. Scrub with soft bristle brush under running hot water. 4. Hot air dry.
5. Weigh.
6. Repeat steps 2 through 5 until
a
constant weight loss/cycle is obtained (and until examination under low magnification reveals that all corrosion products have been removed).The cleaning loss/cycle is the constant loss obtained
after corrosion products have been removed. The corrected
weight loss is the total weight loss minus the (cleaning loss/cycle x the numb er of cycles).
Corrosion Rate
The penetration rate in mil per year was calculated by use of the following formula:
mpy
=
Corrected weight loss (gm) x8.
55Specimen area (s q in.) x Exposure time (Yl'l) Specimen area is 50 sq in. including edges.
Cleaning Solution Used
(1) Ammonium Chloride Solution (Uhlig, H. H. The Corrosion
Handbook, John Wiley and Sons, Inc., N. Y., p. 344). 10%
Balance.
Panels are immersed in this solution at 60°C, with agitation for 5 min/cycle. The cleaning loss/cycle is obtained by repeating cycles until a constant weight loss is attained. The cleaning correction (0.019 gm/cycle) is then subtracted from the total weight loss determined.
A - 2
(2) Chromate Mixture (E. G. Straud, J. App l, Chern.
1951, 1, p. 93). Balance Cr0 3 AgCr0 4 SrCr0 4
H
2°
10% 2% >19% }greater than solubility limit )
Panels are immersed in this mixture at r oorn temperature for 20 min. on the first cycle and 5 min. on subsequent cycles. Adequate stirring must be provided to keep the excess of AgCrO 4
and SrCr04 in suspension. Cleaning cycles are continued until
the weight loss/cycle is negligible.
(3) Ammoniacal Ammonium Acetate Solution
(Formulation based on Cominco Laboratory experience). NH
40H (28%) - 4 parts by volume
H
20 - 4 parts by volume
Glacial Acetic
Acid - 1 part by volume
Panels are immersed in this solution at room temperature
with agitation. It was used during the fir stcleaning cycle of
site 4 panels. Subsequent cleaning was carried out with solution
(1). The cleaning correction of 0.027 gm/cycle was determined
after constant weight loss/cycle with the ammonium chloride solution was attained.
Corrosion Rate Calculation
The penetration rate in mil per year (rnpy) was calculated
using the following formula:
mpy
=
Corrected weight loss (gm) x 8. 55Specimen area (sq in.) x Exposure time (yr) Specimen area is 50 sq in. including edges.
WITH TIME OF P.XPlliUR!':
B-8 ROLLED ZINC -
wr
1 - EXFOSED 1 YEAROriginal Vito After Cleaning Corrected Penetration Site Specimen Wt., Cleaning Wt. Loss. Correction.. Wt. Loss. Rate,
•
セ No. gm gm --&!!i_ gm gm mpy
1 1 285.124 284.830 0.294 0.015 0.279 0.048 2 285.136 284.858 0.278 0.015 0.263 0.045 3 284.280 284.013 0.267 0.015 0.252 0.043 Ave. <:2_.045) 2. 1 288.485 288.325 0.160 0.015 0.145 0.025 2 288.862 288.702 0.160 0.015 0.145 0.025 3 290.978 290.816 0.162 0.015 0.147 0.025 Ave. セ 3. 1 287.227 286.568 0.659 0.015 0.644 0.110 2 290.722 290.066 0.656 0.015 0.641 0.110 3 287.335 286.670 0.665 0.015 0.650 0.111 Ave.
セ
4. 1 287.609 282.052 5.557 0.030 5.527 0.945 2 288.815 283.448 5.367 0.030 5.337 0.912 3 290.108 284.871 5.237 0.030 5.207etm
Ave. oNセ 5. 1 288.301 287.842 0.459 0.015 0.444 0.076 2 285.892 285.431 0.461 0.015 0.446 0.076 3 287.024 286.573 0.451 0.015 0.436セ
Ave. 0.076"I 6. 1 291.450 291.327 0.123 0.015 0.108 0.018 2 284.777 284.694 0.083 0.015 0.068 0.012 3 287.648 287.550 0.098 0.015 0.083セ
Ave. 0. 019
7. 1 285.269 285.084 0.185 0.015 0.170 0.029 2 285.497 285.334 0.163 0.015 0.148 0.025 3 287.485 287.3"11.7 0.168 0.015 0.153セセ
Ave 0.02'0 8. 1 292.297 291.751 0.546 0.015 0.531 0.091 2 290.623 290.120 0.503 0.015 0.488 0.083 3 285.324 284.885 0.439 0.015 0.424 0.072 Ave. CQ.08S'.B-2'
B-8 ROLLED ZINC - LOT 2 - EXPOSED 2 YEARS.
Original Vit. After Cleaning Corrected Penetration
Site Specimen Wt. , Cleaning, Vit. loss, Correction
,
Wt. loss. Rate,セ
No.
gm gm gm gm gm ropy 1. 1 291.691 291.118 0.513 0.030 0.543 0.046 2 291.851 291.261 0.590 0.030 0.560 0.048 1 3 285.734 284.521 1.213 0.030 1.183 0.1011 Ave. CQ..041.) 2 2. 1 281.810 281.592 0.218 0.030 0.188 0.016 2 288.231 288.010 0.221 0.030 0.191 0.011 3 281.897 287.656 0.241 0.030 0.211 0.018 Ave.セ
3. 1 292.314 291. 012 1.362 0.030 1.332 0.114 2 292.191 290.816 1.381 0.030 1.351 0.116 3 291. 899 290.553 1.346 0.030 1.316 0.112 Ave.セ
4. 1 289.924 280.085 9.839 0.030 9.809 0.839 2 289.876 280.010 9.866 0.030 9.836 0.841 3 290.405 280.113 10.232 0.030 10.202セ
Ave. 0.85 5. 1 286.808 286.002 0.806 0.030 0.116 0.066 2 281.321 286.491 0.824 0.030 0.194 0.068 3 281.863 281.063 0.800 0.030 0.710 0.066 Ave.セ
6. 1 284.614 284.553 0.121 0.030 0.091 0.0018 2 285.445 285.314 0.131 0.030 0.101 0.0086 3 285.981 285.842 0.145 0.030 0.115o
0098 Ave.C§::
OOBjo"
1. 1 285.200 284.914 0.286 0.030 0.259 0.022 2 284.951 284.691 0.254 0.030 0.224 0.019 3 284.220 283.951 0.269 0.030 0.239 0.020 Ave.<[;02Q::
8. 1 291.659 290.735 0.924 0.030 0.894 0.016 2 292.001 291.083 0.918 0.030 0.888 0.016 3 284.096 283.111 0.985 0.030 0.955 0.082 Ave.`NセWセ
1. Wt. loss too high
-
error in original wt.7B-8 ROLLED ZINC -- LOT
3 --
EX.! OSED5
YEARS- - - _.. _-_.-.
Original lit. After Cleaning Corrected Penetration
Site Specimen Ht., Cleaning, '-it. Loss, Correction, Wt. Loss
,
Rate,No. No. gm BIll gm Qn &n roPy
1
1
293. 127
291.610
1.517
0.057
1.lK>0
0.050
2
291. 590
290.084
1.5c6
0.057
1.449
0.050
3
2&>.995
285.443
1.552
0.057
1.495
0.051
Average0.050
2
1
287.840
287·382
0.458
0.057
0.401
0.014
2
288.454
287.969
0.485
0.057
0.428
0.015
3
288.600
288.104
0.496
0.057
0.439
0.015
Average0.015
3
1
287.126
283.255
3.871
0.057
3.814
0.130
2
291.952
288.000
3.952
0.057
3.895
0.133
3
291.705
287.888
3.817
0.057
3.760
0.129
Average0.131
4
1
290.8 15
269.296
21·519
0.103
21.416
0·735
2
289.681
268.920
20.761
0.103
20.658
0.707
j289.501
268.776
20.725
0.103
20.622
0.706
Average0.716
5
1
285.2 03
283.560
1.643
0.038
1.605
0.055
2
285.223
283·551
1.672
0.057
1.615
0.055
3
2&>.658
285.052
1.606
Nil1.6c6
0.055
Average0.055
6
1
284.445
284.270
0.175
0.038
0.137
0.0047
2
2e6·312
286.112
0.200
0.057
0.143
0.0049
3
284.163
283.992
0.172
Nil0.172
0.0059
Average0.0052
7
1
284.lK>7
283.913
0·554
0.038
0.516
0.018
2
284.509
283.900
0.609
0.057
0·552
0.019
3
292.673
292.081
0·592
Nil0.592
0.020
Average0.019
8
1
283. 832
281.660
2.172
0.057
2.115
0.072
2285. 162
282.878
2.284
0.057
2.227
0.076
3
287.220
.285.514
1.7c6
Nil1.7c6
0.058
Average0.074*
*
Average of GpeC1mens.
1
and2
only. Error suspected in recordingB-4
ll-R IWLLlW ZINC - LOT 4 - EXJ-'OSED 10 YEj,RS
Odrdnnl Vlt.
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er lIt. Gler:ninp: Corrected Fenet ....ationSit'? Spec irien 1,1+ C1p;mi'w, Loss, co"....ect.i.on, \it. Loss fld,e,
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