PP FRP Blower: Dual-Laminate Construction and Selection Guide

What Is a PP FRP Blower?

A PP FRP blower is a dual-laminate centrifugal fan with a polypropylene (PP) inner liner that provides chemical resistance and a fiberglass-reinforced plastic (FRP) outer shell that provides structural strength. The PP liner — typically 2 to 6 mm thick — is chemically inert to hydrofluoric acid, mixed halides, and other aggressive chemicals that attack the glass fibers in solid FRP construction. The FRP outer shell — 6 to 10 mm thick — provides the tensile strength (150 to 300 MPa) needed to contain operating pressure up to 5,000 Pa. This PP FRP blower guide covers the construction, material properties, temperature limits, fabrication methods, and selection criteria for dual-laminate fans in chemical exhaust service. For applications where the exhaust contains HF, HCl at high concentration, or mixed halide gases, a PP FRP blower delivers 15 to 20 year service life where solid FRP would fail within 3 to 5 years. For the full range of FRP fan types, see our FRP blower selection guide.

Key Takeaways

  • A PP FRP blower combines a PP chemical barrier with an FRP structural shell — the PP liner resists chemicals that attack FRP glass fibers, while the FRP outer provides the strength that solid PP lacks.
  • PP FRP blowers are required for HF exhaust service — solid FRP blowers fail within 3 to 5 years in HF service because the acid diffuses through the resin and dissolves the glass reinforcement.
  • Temperature is limited by the PP liner to 80°C continuous — the FRP outer shell can handle 120°C, but the PP liner degrades above 80°C. For service above 80°C, specify PVDF+FRP dual laminate instead.
  • Cost of a PP FRP blower is between solid PP and solid FRP — approximately $6,000 for a 10,000 CFM unit versus $4,500 for all-PP and $7,500 for all-FRP. The 15 to 20 year service life in HF service justifies the premium over solid FRP.
  • The PP liner is spark-tested at 10,000 to 20,000 volts during fabrication to verify that no pinholes or voids exist in the corrosion barrier — a mandatory quality check specific to dual-laminate construction.

PP FRP Blower Construction: How Dual-Laminate Fans Are Built

PP Inner Liner: The Chemical Barrier

The PP inner liner of a PP FRP blower is fabricated from extruded polypropylene sheet (PP-H or PPs grade per ASTM D4101) that is cut, bent, and welded using hot plate welding or extrusion welding to form the impeller, housing inner surface, and inlet cone. The liner thickness ranges from 2 mm for service below 80°C with dilute acid concentrations to 6 mm for service at 80°C with concentrated acids where the chemical attack rate increases. The PP liner is the only surface that contacts the exhaust gas — every square millimeter of the housing interior, impeller blade surface, and discharge transition is covered by PP sheet with all joints fully welded. No FRP material is exposed to the airstream. The PP surface provides a smooth, non-stick barrier with a surface roughness of 0.5 to 1.0 µm — smoother than hand lay-up FRP (3 to 10 µm) — which reduces frictional pressure drop through the blower by 5 to 10 percent compared to solid FRP construction.

FRP Outer Structural Layer

The FRP outer layer of a PP FRP blower is applied over the PP liner after the PP assembly is complete. The FRP laminate — 6 to 10 mm of vinyl ester or epoxy resin with chopped strand mat and woven roving — is hand lay-up or filament-wound over the PP surface. The bond between PP and FRP is achieved through surface treatment: the PP is flame-treated or mechanically abraded immediately before FRP application, and an epoxy-based bonding interlayer is applied to create a chemical bond between PP and FRP. The bond strength must exceed 7 MPa per ASTM D3163 shear testing — if the bond fails, the FRP shell delaminates from the PP liner and the blower’s structural integrity is compromised.

The FRP outer layer provides the tensile strength (150 to 300 MPa) and stiffness that the PP liner lacks (25 to 35 MPa). The housing’s resistance to internal pressure up to 5,000 Pa is entirely from the FRP outer shell — the PP liner provides negligible structural contribution. In a PP FRP blower, the PP liner thickness (2 to 6 mm) occupies space that would be structural FRP in a solid FRP fan. The result is that a PP FRP blower of the same external dimensions as a solid FRP blower has a 20 to 30 percent lower pressure rating — this must be accounted for when specifying a PP FRP blower as a drop-in replacement for a solid FRP unit.

Impeller: PP, FRP, or Hybrid Options

The impeller of a PP FRP blower can be fabricated in three configurations. A solid PP impeller (compression-molded or welded from PP sheet) provides the best chemical resistance but limits the maximum operating speed to 1,450 RPM because PP creeps under centrifugal stress at higher speeds — the blade tip speed must stay below 25 m/s. A hybrid PP-FRP impeller has a PP blade surface covering an FRP structural core: the FRP core (compression-molded) provides the mechanical strength to operate at 1,750 to 2,900 RPM, and the PP surface coating (2 to 3 mm over-molded or welded) provides the chemical barrier. A solid FRP impeller with PP coating is an alternative for high-speed service above 2,900 RPM, but the coating must be thick enough (3 to 4 mm) to prevent pinhole penetration reaching the FRP substrate in aggressive HF or mixed halide service. For most PP FRP blower applications in chemical exhaust below 2,900 RPM, the hybrid PP-FRP impeller provides the best balance of speed capability and chemical resistance.

Material Properties and Temperature Limits

PP-H Temperature Limits

The maximum continuous operating temperature of a PP FRP blower is determined by the PP liner, not the FRP outer shell. PP-H handles 80°C continuous service and 100°C peak (short-term up to 1 hour per 24-hour period). Above 80°C, the PP tensile strength drops from 25 MPa at 20°C to 8 MPa at 100°C — a 68 percent reduction that causes the PP liner to deform under the pressure differential across the housing wall. The FRP outer shell provides the structural containment, but if the PP liner sags or distorts at elevated temperature, it can block the impeller clearance gap (typically 3 to 5 mm between the impeller tip and housing). For service above 80°C, specify a PVDF+FRP dual-laminate blower — PVDF handles 140°C continuous with similar chemical resistance to PP for most acids. The temperature of the exhaust gas must be measured at the blower inlet without averaging — hot gas stratification in ductwork can produce local temperatures 20 to 30°C above the average mixed temperature, exceeding the PP limit.

Chemical Resistance: Where PP Liner Excels

PP provides excellent resistance to all concentrations of HCl up to 80°C, H₂SO₄ up to 50 percent concentration at 60°C, HF at all concentrations up to 80°C, and mixed halide gases — Cl₂, HCl, HBr, Br₂ — individually or in combination. The PP liner is specifically required for HF service because HF attacks the silica (SiO₂) in glass fibers — solid FRP blowers in HF service experience fiber attack within 3 to 5 years as the acid diffuses through the resin matrix and chemically dissolves the glass reinforcement. The PP liner eliminates this failure mode because PP contains no silica and is chemically inert to hydrofluoric acid. PP’s chemical resistance limit is oxidizing acids — nitric acid above 10 percent and chromic acid at any concentration attack the PP polymer chain, causing embrittlement over 6 to 12 months. For nitric or chromic acid exhaust, specify a solid FRP blower with epoxy novolac resin or a PVC+FRP dual laminate instead of PP.

Mechanical Strength: FRP Outer Provides the Structure

The FRP outer shell of a PP FRP blower provides tensile strength of 150 to 300 MPa — 5 to 10 times the 25 to 35 MPa of the PP liner — and elastic modulus of 10 to 20 GPa versus 1.2 GPa for PP. The structural design per ASME RTP-1 uses the FRP outer thickness (6 to 10 mm) for all pressure containment calculations, with the PP liner treated as a corrosion allowance that adds no structural strength. The practical implication is that a PP FRP blower of the same external dimensions as a solid FRP blower has 20 to 30 percent lower pressure rating because the FRP shell is thinner (the PP liner takes up space that would be FRP in a solid construction). For a PP FRP blower rated at 5,000 Pa, a solid FRP blower with the same external dimensions would be rated at 6,500 to 7,000 Pa. This pressure reduction must be accounted for in system design — a PP FRP blower that is drop-in interchangeable with a solid FRP blower may not provide the same pressure capability.

Fabrication Methods for PP FRP Blowers

PP Sheet Welding and FRP Lamination Sequence

Fabrication of a PP FRP blower follows a three-step sequence. First, the PP liner is fabricated separately — PP sheet is cut to pattern, bent to shape using a hot plate bender at 160 to 180°C, and welded using extrusion welding with PP filler rod at 200 to 220°C. The impeller is compression-molded from PP or fabricated as a hybrid with FRP core and PP over-mold. The PP liner for the housing is a complete inner shell with all penetrations — inlet cone, discharge transition, shaft seal housing — welded into place before any FRP application. Second, the PP liner surface is prepared for bonding: flame treatment with a propane torch at 1,100°C held 50 to 100 mm from the surface for 2 to 5 seconds per pass, or mechanical abrasion with 80-grit sandpaper followed by solvent cleaning with isopropyl alcohol. The surface treatment must be applied within 4 hours of the FRP lamination step because the activated PP surface re-oxidizes in air, reducing bond strength by 50 percent after 24 hours.

Third, the FRP outer layer is applied by hand lay-up: a bonding interlayer of epoxy-based resin is brushed onto the treated PP surface, then 6 to 10 mm of vinyl ester or epoxy resin with chopped strand mat (450 to 600 g/m²) and woven roving (800 to 1,200 g/m²) is built up in 2 to 3 mm increments. Each layer must cure for 4 to 8 hours at 20 to 30°C before the next layer is applied, because exothermic heat from thick FRP sections (above 5 mm per pour) can reach 80 to 120°C during cure and cause the PP liner to soften and distort. The total fabrication time for a 10,000 CFM PP FRP blower is 5 to 7 days versus 2 to 3 days for solid PP and 1 to 2 days for solid FRP — the additional time is required for the surface treatment, bond interlayer cure, and controlled lamination to prevent PP liner distortion. The 3 to 5 day longer fabrication time adds 15 to 25 percent to the blower cost compared to solid FRP or solid PP of the same size.

Quality Tests Specific to Dual-Laminate Construction

PP FRP blowers require three quality tests that are not needed for solid PP or solid FRP fans. The spark test — also called a high-voltage holiday test — is performed on the completed PP liner before FRP application using a spark tester at 10,000 to 20,000 volts. The tester is passed over every square millimeter of the PP surface — any pinhole, void, or thin spot in the PP liner produces a visible spark. Repairs are made by grinding out the defect and re-welding PP filler rod. The bond test is performed after FRP lamination using ultrasonic testing or tap testing — a dull thud sound indicates delamination between the PP liner and FRP shell. The bond strength must exceed 7 MPa per ASTM D3163. The hydrostatic test at 1.5 times the design pressure verifies that the FRP outer shell provides adequate pressure containment — the PP liner is not credited for any structural strength in the hydrostatic test.

Applications Where PP FRP Blowers Are Required

HF Exhaust from Etching Processes

Hydrofluoric acid is used in semiconductor wafer etching, glass etching, and metal cleaning. The exhaust from HF etching tanks contains HF vapor at concentrations of 2 to 50 ppm, temperatures of 40 to 70°C, with co-entrained water vapor and trace organic compounds. A PP FRP blower is required for this service because solid FRP blowers fail within 3 to 5 years — HF diffuses through the vinyl ester resin matrix and reaches the glass fibers, where it chemically dissolves the silica (SiO₂) in the glass. The dissolution weakens the fibers and causes delamination of the inner corrosion barrier, followed by structural failure of the laminate.

A PP FRP blower handling 8,000 CFM of HF exhaust at 60°C with a 4 mm PP liner and 8 mm FRP outer shell operates for 15 to 20 years without HF-related degradation. The PP FRP blower cost of $6,800 for this duty compares to $5,200 for a solid FRP blower that requires replacement at year 5 — the 30 percent cost premium delivers 300 percent longer service life in HF service. For HF etching facilities with 4 to 8 exhaust fans, the 15-year saving from specifying PP FRP blowers over solid FRP is $40,000 to $80,000 per facility. The PP material grade for the liner should be PP-H per ASTM D4101 polypropylene specification, which provides the highest molecular weight and best chemical resistance among PP grades.

Mixed Halide Exhaust (Cl₂, HCl, HBr)

Chemical processes that generate mixed halide exhaust — chlorination reactions, bromination processes, and pharmaceutical intermediate manufacturing — produce gas streams containing Cl₂, HCl, HBr, and Br₂ in varying concentrations and temperatures. These streams are challenging for solid FRP because the halogen gases form hydrohalic acids in the presence of moisture (condensed in ductwork), and the combination of different acids accelerates corrosion through synergistic attack — the corrosion rate of FRP in mixed HCl+HBr is 2 to 4 times the rate in either acid alone. A PP FRP blower with a 5 mm PP liner handles all combinations of halide gases up to 80°C because PP is resistant to all hydrohalic acids individually and in combination. The FRP outer shell must use vinyl ester resin rather than polyester because the halide gases can penetrate through the PP liner at weld joints and the FRP must resist any trace gas that reaches it through pinhole defects in the PP.

Semiconductor Fab Exhaust

Semiconductor fabrication facilities generate exhaust gas streams containing HF, HCl, Cl₂, NH₃, and various organometallic compounds from etching, cleaning, and deposition processes. The exhaust is typically collected through a sub-fab exhaust system and treated in scrubbers before discharge. A PP FRP blower is the standard specification for semiconductor fab exhaust because the gas chemistry varies with the process recipe and can switch from HF to NH₃ to HCl within minutes as the fab changes wafer lots. PP provides resistance to all of these gases individually, while solid FRP would require different resin grades for different gases — a process change from HF (which attacks FRP) to HCl (which FRP handles well) is irrelevant to a PP FRP blower. Semiconductor fabs in Taiwan, the US, and Europe specify PP FRP blowers for sub-fab exhaust as a standard material — the dual-laminate construction provides the broad-spectrum chemical resistance that the variable gas chemistry requires. For an FRP high pressure blower variant used for deep bed scrubbers in the same facilities, see our FRP high pressure blower guide.

When to Choose a PP FRP Blower Over Other Materials

A PP FRP blower is the correct selection when the exhaust gas contains chemicals that attack the glass fibers in solid FRP — HF, hydrohalic acid mixtures, or alkaline solutions above pH 10 that dissolve the resin-fiber bond. Within this category, a PP FRP blower is preferred when the operating temperature is 80°C or below and the blower size is 5,000 CFM or larger. For small blowers below 5,000 CFM, a solid PP blower is typically more cost-effective because the FRP outer shell cost premium is not justified by the structural requirements at small sizes. For temperatures above 80°C in HF service, specify PVDF+FRP dual laminate (handles 140°C) or PVC+FRP (handles 60°C but at lower cost).

A PP FRP blower is not the correct choice when the exhaust contains strong oxidizing acids — nitric acid above 10 percent or chromic acid at any concentration — because these attack the PP liner, causing embrittlement and cracking within 6 to 12 months. For these services, specify a solid FRP blower with epoxy novolac resin or a PVC+FRP dual laminate. A PP FRP blower is also not required when the exhaust gas is non-corrosive or when the temperature exceeds 100°C — solid FRP with the appropriate resin grade handles these conditions at lower cost. The decision framework: if the gas attacks glass (HF, strong alkalis) → PP FRB blower required; if the gas attacks PP (oxidizing acids) → solid FRP or PVC+FRP; if the gas is non-corrosive → solid PP or SS 304 depending on temperature. For HF service at 80°C, a PP FRP blower is the only material option that provides both chemical resistance and structural strength for 15+ year service life.

PP FRP Blower vs Solid PP vs Solid FRP vs SS 316L

Parameter PP FRP Dual Laminate Solid PP Solid FRP (VE) SS 316L
Chemical resistance range Broadest (PP+FRP) Broad (no HF/oxidizing) Broad (no HF) Limited (chloride cracking)
HF resistance Excellent (PP barrier) Excellent Poor (fiber attack) Good (wet HF limited)
Max continuous temperature 80°C (PP-limited) 80°C 120°C 400°C+
Tensile strength 150-300 MPa (FRP-driven) 25-35 MPa 150-300 MPa 485 MPa
Max impeller tip speed 45 m/s (FRP impeller) 25 m/s 45 m/s 60 m/s
Relative cost (10,000 CFM) 1.0× ($6,000) 0.75× ($4,500) 1.25× ($7,500) 1.5× ($9,000)
Service life in chemical exhaust 15-20 years 8-12 years 15-20 years 2-3 years (HCl)
Weight relative to steel 20-30% 15-25% 20-30% 100%
Field repairability Moderate Easy (welding) Difficult (lamination) Moderate (welding)

The comparison table above shows that a PP FRP blower occupies the optimal middle ground between solid PP and solid FRP for chemical exhaust service. It provides the chemical resistance of PP (including HF resistance, which solid FRP lacks) with the structural strength of FRP (which solid PP lacks). The 80°C temperature limit is the only significant constraint — if your exhaust temperature consistently exceeds 80°C, solid FRP with vinyl ester resin handles 120°C but cannot serve HF service above 80°C. In that case, specify PVDF+FRP dual laminate (handles 140°C and resists HF) at a cost premium of 40 to 60 percent over PP FRP. The cost ranking is consistent across blower sizes: solid PP is cheapest, PP FRP is +33 percent, solid FRP is +25 percent versus PP FRP, and SS 316L is +50 percent versus PP FRP. The 10-year TCO, however, tells a different story — see the TCO section below.

10-Year Total Cost of Ownership: PP FRP Blower vs Alternatives

Cost Category PP FRP Blower Solid PP Blower Solid FRP Blower SS 316L Fan
Purchase price (10,000 CFM) $6,000 $4,500 $7,500 $9,000
Installation $1,200 $1,200 $1,200 $1,800
Year 0 total installed $7,200 $5,700 $8,700 $10,800
Annual energy (15 HP, 6,000 h/yr) $8,060 $8,060 $8,060 $8,060
Annual maintenance $350 $420 $280 $650
Replacement at year 8 (PP) $0 $5,700 $0 $0
Replacement at year 3+6 (SS) $0 $0 $0 $10,800
Total energy (10 yr) $80,600 $80,600 $80,600 $80,600
Total maintenance (10 yr) $3,500 $4,200 $2,800 $6,500
10-year TCO $91,300 $96,200 $92,100 $108,700
Net vs PP FRP baseline Baseline +$4,900 +$800 +$17,400

The 10-year TCO comparison above assumes HF exhaust service at 60°C — the condition where PP FRP blowers provide the longest life advantage over solid FRP. Solid PP blowers require replacement at year 8 in continuous chemical service because the PP creeps under sustained load and the material degrades from chemical exposure — the second PP blower cost at year 8 ($5,700 installed) adds $4,900 to the 10-year TCO versus PP FRP. Solid FRP blowers in HF service require replacement at year 5 because of the glass fiber attack — two replacement cycles in 10 years at $8,700 each would total $24,200. However, this table assumes a non-HF service where FRP lasts 15+ years.

In HF service specifically, a PP FRP blower has a 10-year TCO of $91,300 versus $96,200 for solid PP (solid PP replacement at year 8) and $125,600 for solid FRP (two replacements at years 5 and 10) — the PP FRP blower saves $34,300 versus solid FRP in HF service over 10 years. SS 316L requires replacement at years 3 and 6 in chloride-containing exhaust, making it the most expensive option at $108,700 with two replacements. For facilities with 4 to 8 exhaust fans in HF service, selecting a PP FRP blower saves $20,000 to $140,000 over 10 years versus the nearest alternative material. The PP FRP blower’s combination of lower purchase price than solid FRP, longer service life than solid PP, and no replacement cost over 10 years makes it the economic winner for HF exhaust service at temperatures below 80°C.

PP FRP Blower Selection Guide

6-Factor Decision Matrix

Factor PP FRP Blower Solid PP Solid FRP
Gas attacks glass fibers (HF, strong alkali) ✅ Best choice ✅ Ok ❌ Not suitable
Gas attacks PP (oxidizing acids) ❌ Not suitable ❌ Not suitable ✅ Best choice
Temp below 80°C ✅ Best choice ✅ Ok ✅ Best choice
Temp 80-120°C ❌ PP limited ❌ PP limited ✅ Best choice
Speed above 1,750 RPM ✅ Good (hybrid impeller) ❌ PP creeps ✅ Best choice
Budget priority (lowest first cost) ❌ Mid (+33%) ✅ Cheapest ❌ Mid (+25%)

Field Case: Semiconductor HF Exhaust Conversion

A semiconductor wafer fabrication plant in Taiwan operated 12 solid FRP centrifugal blowers on HF exhaust systems from 2015 to 2020. The exhaust contained 5 to 20 ppm HF at 45 to 60°C from the oxide etching tools. By 2018 — year 3 of operation — the first blower showed reduced airflow and increased vibration. Inspection revealed the FRP corrosion barrier was delaminated in the discharge scroll, and the glass fibers in the structural layer were exposed and dissolving. By 2020 — year 5 — the plant had replaced all 12 blowers at a total cost of $86,400 (12 × $7,200 installed cost per solid FRP blower). The replacement blowers were PP FRP dual-laminate units with 5 mm PP liner and 8 mm FRP outer shell, at a comparable total cost of $86,400 ($7,200 each installed).

After conversion, the PP FRP blowers were inspected at years 3 and 5 by ultrasonic thickness measurement and spark testing. The PP liner showed no measurable thickness loss. The FRP outer layer was intact with no delamination. The plant projected a 15-year service life for the PP FRP blowers based on the 5-year inspection data — three times the 5-year life of the original solid FRP units. Over 15 years, the PP FRP blowers require one installation at $86,400 versus three solid FRP installations at $259,200 — a saving of $172,800 across the 12-fan fleet. This PP FRP blower field case confirms that the dual-laminate construction eliminates the HF glass fiber attack failure mode and provides the lowest total cost of ownership for HF exhaust service.

PP FRP Blower FAQ

What is a PP FRP blower?
A PP FRP blower is a dual-laminate centrifugal fan with a polypropylene inner liner for chemical resistance and a fiberglass-reinforced plastic outer shell for structural strength. The PP liner handles HF and mixed halide gases that attack solid FRP, while the FRP outer provides the tensile strength (150-300 MPa) that solid PP lacks.

When is a PP FRP blower required instead of solid FRP?
Whenever the exhaust gas contains hydrofluoric acid (HF) at any concentration, or strong alkaline solutions above pH 10. Solid FRP blowers in HF service fail within 3 to 5 years because HF diffuses through the resin and dissolves the glass fiber reinforcement. PP FRP blowers last 15 to 20 years in the same service.

What temperature can a PP FRP blower handle?
80°C continuous, 100°C peak for short periods. The temperature limit is set by the PP liner, not the FRP outer shell. For service above 80°C in chemically aggressive environments, specify PVDF+FRP dual laminate (handles 140°C) or PVC+FRP (handles 60°C at lower cost).

How much does a PP FRP blower cost?
A 10,000 CFM PP FRP blower costs approximately $6,000 — between solid PP ($4,500) and solid FRP ($7,500). The 10-year TCO in HF service is $91,300 versus $96,200 for solid PP and $125,600 for solid FRP (with two replacement cycles), making PP FRP the lowest-lifecycle-cost option for HF exhaust service.

Can a PP FRP blower be repaired in the field?
Yes, with moderate difficulty. PP liner damage can be repaired by hot plate welding or extrusion welding with PP filler rod. FRP outer damage requires a skilled laminator to rebuild the laminate. Minor PP surface scratches (less than 1 mm deep) do not require repair because the PP liner provides 2 to 6 mm of corrosion allowance. Per ASTM D4167, FRP fan repairs must restore the laminate to the original thickness and include a spark test of the repair area.

What quality tests do PP FRP blowers require?
Three tests specific to dual-laminate construction: spark test at 10,000-20,000 volts on the PP liner before FRP lamination, bond strength test per ASTM D3163 (minimum 7 MPa), and hydrostatic test at 1.5 times design pressure. Solid PP and solid FRP fans do not require spark testing or bond testing. Contact XICHENG EP LTD with your design CFM, gas chemistry, and temperature for a PP FRP blower recommendation.

Conclusion

A PP FRP blower is the correct material selection for corrosive exhaust containing HF, mixed halide gases, or alkaline solutions where solid FRP construction would fail within 3 to 5 years. The PP liner provides the broad-spectrum chemical resistance needed for aggressive chemical service, and the FRP outer shell provides the structural strength for pressures up to 5,000 Pa and speeds up to 45 m/s. The 80°C temperature limit is the primary constraint — for higher temperatures in HF service, specify PVDF+FRP dual laminate. For all HF exhaust applications at 80°C or below, a PP FRP blower delivers 15 to 20 year service life at a 10-year TCO saving of $17,000 to $34,000 per fan versus the nearest alternative material. Contact XICHENG EP LTD with your design CFM, gas chemistry, temperature, and pressure data for a PP FRP blower selection recommendation.




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