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Latest revision as of 08:22, 15 March 2020
| ML20023D146 | |
| Person / Time | |
|---|---|
| Site: | LaSalle, 05000000 |
| Issue date: | 08/27/1982 |
| From: | Cho F, Kisisel I, Meligi A SARGENT & LUNDY, INC. |
| To: | |
| Shared Package | |
| ML20023A480 | List: |
| References | |
| FOIA-82-366 CQD-003490, CQD-003490-R00, CQD-3490, CQD-3490-R, NUDOCS 8305190303 | |
| Download: ML20023D146 (27) | |
Text
{{#Wiki_filter:. . CAR 2ENT Q LUNDY
. ,- E N GIN E E RO CHICAGO -
ASSESSMENT OF STITCH WELD STRENGTH IN HVAC DUCTWORK CONSTRUCTION LA SALLE COUNTY STATION UNITS 1 &2
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u l i Prepared by Component Qualifica. tion Division l for COMMONWEALTH EDISON COMPANY I .I _g I I
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Report No. CQD-003490 Rev. 00 g'_ . August 27, 1982 I 8305190303 030311 I PDR FOIA PRENDER82-366 PDR
y._ CAR 2ENT Q LUNDY ! EN GINEE RO CMICAGO I
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Prepared by: F. L. Cho, Consultant /M. M. Hassaballa, Supervisor Reviewed by: bl$
- 1. T. Kisisel - Senior Engineering Specialist Approved by': Y A. E. Meligi A ivision, Head i
F l 6 , t Report No. CQD-003490 Rev. 00 August 27,1982 I
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l l SARGENT ar LUNDY
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EN GIN EERS CMICASO
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' TABLE OF CONTENTS :
Page i Introduction ---------------------- i4---------------- 1 . B a c k g ro u n d - - -- - - - - - - - - - - - - - - -- - - -- - - -- - - - - - - - - - - - - - - 2 Objective ------------------------------------ ------ 2 Design Consideration -------------------------------- 3' Test Program ---------------------------------------- 4 , Observation & Interpretation of Test Results -------- 6 Conclusions ----------------------------------------- 7
. Appendix A - Representative Design Cases ------------ 8 Appendix B - Test Results --------------------------- 13 Appendix C - Photographs of Test Samples ------------ 18 O
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.- - - + - - -, , -y . 4 - - -- ve- - - -
9'*r CARGENT Q LUNDY l f . ENGlNTERS CHICAGO C u - ASSESSMENT OF STITCH WELDS STRENGTH IN HVAC DUCTWORK CONSTRUCTION FOR LA SALLE COUNTY NUCLEAR STATION UNITS 1 & 2, INTRODUCTION This report presents a summary of Sargent & Lundy Engineers (S&L) assessment G Q and evaluation of the strength of quality control rejectable stitch welds, used in ductwork construction in' LaSalle County Nuclear Station (LSCS) units
] 1 & 2. .The stitch, welds under consideration join the duct to the companion angle flange in some safety-related HVAC systems. The overall scope of this
. report is addressed in the following sections:
I - Background II - Objective III - Design Consideration p IV - Test Program kJ V - Observation & Interpretation of Test Results
., VI - Conclusions d Appendix A - Representative Design Cases Appendix B - Test Results t
Appendix C - Photographs of. Test Saraples m y , ,- , N C I wh-La R " JF-
- CARGENT Q LUNDY
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1 I. BACKGROUND The HVAC ductwork construction and installation for LSCS is contracted to the ZACK Company. Their ducts are constructed in the shop in four feet l sections with companion angle flanges welded on both sides of'the section (see fig.1). Then the duct sections are joined together in the field by means of flange bolts or Huck screws. All duct sections constructed are shipped to the site after passing the ZACK Quality Control Procedure CQP-20 which is approved by the Commonwealth Edison Company (CECO) and their I Architect / Engineer (S&L). It was discovered that an unqualified welder has performed some work on Safety-Relatid ducts for units 1 & 2. Therefore , CECO has initiated a field inspection program for the affected HVAC duct systems in accordance with QCP-20. 1 The program was conducted by personnel from CECO Q.C. , ZACK Q.C. and CECO's independent Q.C. reviewer (CONAM). It resulted in finding some rejectable I stitch welds in accordance with ZACK CQP-20. These welds fall under the following four major categories.: undercut porosity bad profile lack of fusion A test program was authorized by CECO for the assessment and evaluation of the adequacy of Q.C. rejectable stitch welds. 64 random samples of Q.C. I rejectable stitch welds were selected from different duct sizes taken from the affected duct systems in unit 2. The samples comprise all previously l mentioned i'our categories 'of weld deficiencies in addition to some Q.C. l acceptable stitch welds for comparison. f II. OBJECTIVE
. The objective of this assessment program is to correlate the design aspects of the stitch welds as documented at S&L to the strength of Q.C. rejectable welds based on the test program and the margin of safety existing, if any.
I In other words, to find.out whether or not the Q.C. rejectable stitch welds can resist the postulated design loads with adequate margin of safety and maintain the structural integrity of the affected Safety-Related HVAC f , systems. I -
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Ij CARGENTO LUNDY . i H .
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! III. DESIGN CONSIDERATIONS l The stitch welds under consideration join the duct sheet metal to the companion angle flange (see fig.1). They are fillet types with a ( < -q _ nominal length of 1.0" and throat dimension of 0.125" (1/8) and 0.1875" d (3/16) depending upon the duct size. The welds are spaced every 8" along the duct to companion angle flange joint periphery. Spacing and sizing of the welds are governed primarily by leak tightness requirements for the joint and by usual construction practice, not by ! the required weld strength. In addition, the design of duct systems is based solely on the governing sheet metal stresses. It is obvious from
- E duct construction that (see fig.1) the vertical and transverse shear forces and out-of-plane bending moments at the joint cross-section will be transmitted to the stitch welds as shear force.
E - Companion Angle E
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= Test Sample (see fig. 2)
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" Huck" Bolt-lg .
1.8"Stitch o weieq n+ l 0.C. ' g . ,5 - Joint Detail Figure .f I Typical Duct Section
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CARGENT & LUNDY
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Appendix A delineates the four most representative cases for t.SCS ducts. One can easily observe that the maximum load / stitch weld due to internal l-pressure, weight and postulated dynamic loads does not exceed 400 lbs. In other words, the stitch weld is not resisting more than 400 lbs ' regardless of the duct size and spacing. This load translates to a l stress of 3200 psi in the weld. The design load for 1/8" throat fillet weld is 2400 lbs/in per AISC design specicification for E70 welding I h electrode. ' The aforementioned discussion attests to the fact that the duct design is I 9overned by sheet metal strength. Hence, in a hypotiietical case of failure the duct sheet metal will reach the material ultimate stress long before the stitch weld reaches its design load. I IV. TEST PROGRAM l The purpose of this program is to determine the strength of "Q.C. rejectable stitch welds" based on random sampling. The, test has been conducted at Pittsburg Testing Lab., Hillside, IL on 8/16/82. Test Specimen Configuration Figure 2 depicts a typical dimension of the random test samples in order to simulate the existing installation ~ condition.
' Sheet Metal Companion Angle g e
-----> Applied Force 4 = 4- - .- - '
E Stitch [" Weld 10" r
' s.
Companion Angle
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~~d - -> Applied Force e
Stitch Weld y r] L + -- - _4 Sheet Metal
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D" Figure 2 Typical Test Sample
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. CAR 2 ENTO LUNDY 8! ENGINEERO CHICAGO l
- g Determination of Test Samples There are a wide range of variation in the sizes of companion angles as '
well as the thickness of sheet tr.: tal in ductwork construction, coupled , _ with various defective or rejectable welds per E70 Electrode weldment for I ductwork joint construction. The following Lists-(a) & (b) show the representation of test samples for f *
" Pull" test:
(a) Type of " stitch welds" Sample I 1. Q.C. acceptable weld
- 2. Undercut weld
!'. 3. Porous weld
- 4. Bad profile weld
- 5. Lack of fusion in weld (b) Thickness of Sheet Metal for Ductwork Construction I A. 22 GA (0.0312")
B. 20 GA (0.0375") C. 18 GA (0.050") ( D. 16 GA (0.062")
$ Thus, the designation of test saniple shal'1 be shown as follows:
Sample E, Category . No. 1 A' - II 3 Sample Sequence No.
. Thickness of Sheet Metal 5 Type of " Stitch Weld" The total of 64 test samples has been subjected to " Pull" test for reflecting proper representation of physical cases.
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CARCENT O LUNDY EN GIN EE R S CHICAGO Test Description Each sample was clamped to the sitationary jaw of the test machine at the
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sheet metal section (see fig. 2). The pull load (shear force on the weld) applied to the weld via 3/8" bolt attached to test fixture which in turn is connected to the moving jaw of the test machine. The applied load was E ' "c r" d S r' d "' " ' " " " r ' ' ' " d ' c' d * "' r '""' " ' separation or yielding of the companion angle (bolt punching through). V. OBSERVATION & INTERPRETATION OF TEST RESULTS (see Appendix B)
- 1. Failure of the tested samp.les were either cracking of the sheet I metal or yielding of the companion angle. In either case the welds were still intact after the test.
- 2. A summary of the governing results is shown in Table 1 of .
Appendix B, where the highest (upper bound) and lowest (lower bound) failure loads are listed for all weld categories. l l It is clear from Table 1 that var.iation of the upper / lower bound loads exist for all weld categories including Q.C. accepted weld. These ranges of variation are not of .a concern because of the l .following reasons: .
- a. Variation in the actual weld sizes from the minimum specified.
- In other words, the actual weld sizes are usually larger
' than the specified value.
- b. Variation of eccentricty ex (see fig. 2). This leads to imposed additional moment on the weld coupled with stress concentration (stress riser) which in turn causes premature failure of the welded connection.
However, for conservatism,Q.C. rejectable weld allowable will be l based on the lower bound failure loads.
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. CARCENT O LUNDY ,
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- 3. A conservative pseudo allowable load per Q.C. rejectable stitch weld can be interpreted as the Statistical Average of the lower
) bound' failure Load _(SAL) for th'e four rejectable weld categories
- (2 + 5) for 22 gage sheet metal case which is the governing case.
Hence, SAL = 2050 + 1930 + 1890 + 2200 = 2018 lbs - 2000 lbs. Therefore, the pseudo Allowable Load for "Q.C. rejectable weld" 1s 2000 which compares very favorably with the minimum lower l bound load of 1890 lbs. CONCLUSIONS In Section III we established that the actual design load per stitch weld I does not exceed 400 lbs regardless of duct size. In addition, we state,d that the duct design is governed by duct material strength. I ~ In Section V we established a conservative pseudo "Q.C. rejectable stitch weld" allowable load of 2000.lbs. This allowable is based on actual test data regardless of duct sheet metal thickness or companion angle size. Furthermore, the test program proved the fact that the weakest link in the g lm , duct joint 'is the sheet metal or' the companion angle but not the Q.C. rejectable welds. I Based on the above stated ' facts.we can , deduce th'at the strength of "Q.C." rejectable stitch weld" is far higher than the postulated design loads with a ! margin of safety of 5.0 (2000/400). Therefore, it 'is concluded that the "Q.C. rejectable stitch Welds" shall be able to withstand the postulated . design loads and maintain the ?,tructural integrity of the duct to companion angle flange joints in LSCS HVAC safety-related duct assemblies. I I I . L7
SARGENT & LUNDY E N G1N E E RS CMlCAGO
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I l I I I I APPENDIX _A
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l Representative Design Cases I iI . I _ l l1 l l
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-, .--+e e ==+ men eee e. === "- - E e eso em h . APPENDIX - A G .
_ TYPICAL HVAC DUCT SYSTEM .
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y eANess I COMPANION E ANGLE . g . . . . . E
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a no e o e B b f
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. SARGENT &.LUNDY
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APPENDIX - A B _ -REPRESENTATIVE DESIGN CASES E CASE NO.: 1 l FORCE / WELD DATA I N LB S . Duct Size = W x H W = 48" H = 18" Langth of. Duct Section - Weight + DL* 248.51 L = 10.66' . ! Component Weight g , P.= 476.0 Distributed Duct Weight Internal Pressure ** Wd = 36.4 lbs/ft < 150 l
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I Distance Between Stiffeners a = 30" Thickness of Duct (Gage) - 18 Resultant t = 0.05" 398.51' -400 Thickness of Companion Flange Angle T= 1/8" Note: For detail analysis see S&L CQD File No. CQD-003560 .-
- DL - Dynamic Loads 9" Water Column
. !~
6-SARGENT & LUNDY ENGINEERS- ~ CMICAco APPEN51X-A N. O REPRESENTAll & DESIGN CASES . CASE NO.: 2
/
' FORCE / WELD DATA IN GS.
Duct Size = W x H , W = 32" g H = 48" Length of Duct Section - Weight + DL* 62.74 lbs. L = 7.833 Compcnent Weight P = 198 lbs. p Distributed Duct Weight Internal Pressure ** Wd a 44 lbs/ft. <l70 Distance Between Stiffeners
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l Il a = 30" NJ Thickness of Duct (Gage) - 18 Resultant t= 0.05" ~240. Thickness of Companion Flange Angle T = 1/8" ( Note: For detail analysis see S&L CQD File Eo. CQD-003560 s
- DL - Dynamic Loads
** 10" Water Column
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SARGENT & LUNDY
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' APPENDIX - A REPRESENTATIVE DESIGN CASES .
CASE NO.: 3 E FORCE / WELD DATA I N LB S . Duct Size = W x H W = 32" H = 30" tength of Duct Section __ Weight + DL* L = 4,167" 74.44 - Component Weight P = 398 lbs . Distributed Duct Weight Internal Pressure ** Wd = 25.66'1bs/ft <170 Distance Between Stiffeners
. a = 36" -
Thickness of Duct (Gage) 20 Resultant t = 0.0375" - 250 Thickness of Companion Flange Angle T = 1/8" Note: For detail analysis see S&L CQD File No. CQD-003560
- DL - Dynamic Loads
** 10" Water Column l <
4 SARGENTarLUNDY i E N GIN E E R S f F i CMICAso k i . t I
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- APPENDIX B ;
- A Summary of the Governing Samples (Table 1)
! - Specific Failure Mode and Load for ! l 64 Test Samples
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- l. 0 ARGENT O LUNDY E N GlN E E R S I Table 1 A Sumary of the Governing Samples l
I Thickness A* B C D of sheet metal 22 20 18 16 Weld I Category (0.0312") (0.0375") (0.050") (0.062") 1 3020 IV ~.3760 VI 3490 IV 5650 II 1 (Acceptable Weld) T606 I 2680 IV 2810 I 471I6 IV
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2 2190 1 2040 I 3270 II 6180 II (Undercut Weld) 2050 II 2880 V 0000 I 3 3020 II 3530 I 3160 III 6620_ I T936 I 3T!r6 V 2360 II 5530 IV (Porous Weld) 4 2720 I 3360 I 3210 I 3070 I (Bad Profile Weld) 1890 II 2330 IV 3000 III
** ** 4820 I 5 2200 I **
(Lack of Fusion Weld)
- Governing. Cases
** Not Available g
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CARGENTQ LUNDY -
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1 Specific Failure Mode and Load for 64 Test 'Ssn.ples , DJctwork Weld Failure - ,
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Gauge Sample Size Failure Load Category (GA) Number (inches) Mode (1bs) f@ma' r ks l 1.A 22 22 1 V 1-1/2x3/16 1-9/16x3/16 CS CS 1600. 3130. e x =1", ,
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ey=7/8" [, ' 22 IV 1-1/2x3/16 CS 3020. ' " h. , 3 , 22 II 1-1/2x5/32 CS 3130. NN.
- 22 III 1-7/16x3/16 CS 1770. ..'-
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1.3 20 III 1-9/16x7/32 PA 2800. , l ' 20 I i-3/16x3/16 CS 3030. 20 II~ 2x3/16 PA 2480. , 20 IV 1-3/16x7/16 - CS 2680. 20 V 1-3/4x5/32 ' CS . 2800. 20 VI 1-9/16x3/16 PA 3760. , l d 2.A 22 ,I 15/16x5/222 CS 2190.
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2050. n 22 II 1-9/16x5/32s- '- CS ,
'CS- 2040. - %
2.B 20 I i-1/4x7/16 3.A 22 I' i1-7/8x5/32 .CS 1930, s 22 1-5/16x5/32 CS 2720. l II
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, III 1 7/32x5/32 CS 3020.
22 , 22 IV ~ 1 1/2x3/16 CS. 2560.
' ' ' '-8x7/is c5 as30.
E 20 II 1-5/8x3/16 PA 3520. ,
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20 III 1-1/4x3/16 CS 3410. . s> . 3310. [ 20' IV 1-3/16x3/16 CS ' 3150. l. 20 V 1-3/32x5/32 CS a. E
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_,*S CS - Cracking of Sheet Metal PA - Punch through Angle E - _ _ _
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*< CMIC AGO i , v.
I !Metwork ' Weld Failure
< Gauge Sample Size Failure Load Mode (1bs) Remarks Numhr. _(inches)
^
- m. 're.tegorg _ (GA) _
S ,4.A' 3 22- I' " 1-1/4x3/16 CS 2720. 3, .' N 22 II 1-1/8x5/32 CS 1890. 7, . 22 III 1-3/16x;/32 CS 2250. l 3360. - 4.B 20 1 1-9/32x5/32 CS 20 II 1-1/2x3/16 CS 2890.
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20 III 1-3/8x5/32 CS 3250. I ' . .i s
. 20 IV 1.7/8x3/16 CS 2330.
g , 5.A 22 I 1-5/8x3/16' CS 2200. e =3/4", e y=7/8" x
'l 1.C 18 I 1-3/4x1/8 PA 2810.
^
18 11 x1-5/dx5/32 - PA 3070. I ' 18 Ilf' ' 1-1/2x5/32 PA 3230.
., 18 , IV ' 1-9/16x5/32 PA 3490.
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18, ~V s',1-11/16x5/32 PA 3430. ln l
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- 2.C 'D3 I. 1-11/1'-7/32 PA 3020. .
l ,' . la II 1-3/4x3/16 PA 3270. (j - 18 III . 1-1/2x3/16 PA
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3010. 18 , IV 3 1-5/16x3/16 PA 2920.
< 18 . V 1-1/,4x7/16 PA 2880.
i ' 18' I 1-3/8x5/32 PA 2940. l 3 .' C 18 II 1-1/2x3/32 PA 2380. With 3/8" hole nearby s I '
, 18 III 1-5/16x5/32 PA 3160.
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- 18 IV i-5/'.6x5/32 PA 2920.
18 Y 1-5/16x5/32 PA 2890. E .) x, ' lE-
;- - n ~ _ . . . . ~ - . . . . . .
CAPGENTEtLUNDY
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I Weld Failure Ductwork ' Gauge Sample Size Failure Load (1bs) Remarks I Category (GA) Number (inches) Mode 3210. Plug weld in back side 44 18 I 1-11/32x5/32 PA l 18 II 1-5/32x1/8 PA 3040. 18 III 2-1/4x3/16 PA 3000. - I 1.D 16 I 1-15/32x5/:i2 CS 5370. 5650, 16 II 1-3/8x3/16 PA g 16 III 1-17/32x3/16 CS 5430. l 16 IV 1-7/16x3/16' CS 4760. 16 V ~1-13/32x3/16 CS 5350. I 2.0 16 I 1-5/Gx3/16 PA 6000. 16 II 1-1/2x3/16 ~ PA 6180. g 3.D 16 I 1-5/8x3/16 CS 6620.- 3/8" of crater 16 II 1-1/2x3/16 CS 6280. 16 III 1-5/8x3/16 PA 6630._ E 16 IV 1-9/16x3/16 CS 5530.
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4o 'S ' '-5'8*5' ' "^ 7-I 5.D 16 I 1-1/2x3/16 CS 4820. 1/2" .of crater E
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h e SARGENT O LUNDY EN GIN E ERS CMICAGO I s s N
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APPENDIX C l Photographs of Test Samples
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