CA2056909A1 - Flowable building material - Google Patents
Flowable building materialInfo
- Publication number
- CA2056909A1 CA2056909A1 CA 2056909 CA2056909A CA2056909A1 CA 2056909 A1 CA2056909 A1 CA 2056909A1 CA 2056909 CA2056909 CA 2056909 CA 2056909 A CA2056909 A CA 2056909A CA 2056909 A1 CA2056909 A1 CA 2056909A1
- Authority
- CA
- Canada
- Prior art keywords
- material according
- additionally comprises
- base material
- hydraulic binder
- particle size
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B18/04—Waste materials; Refuse
- C04B18/16—Waste materials; Refuse from building or ceramic industry
- C04B18/165—Ceramic waste
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/91—Use of waste materials as fillers for mortars or concrete
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Structural Engineering (AREA)
- Materials Engineering (AREA)
- Civil Engineering (AREA)
- Organic Chemistry (AREA)
- Environmental & Geological Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Inorganic Chemistry (AREA)
- Panels For Use In Building Construction (AREA)
- Processing Of Solid Wastes (AREA)
- Finishing Walls (AREA)
Abstract
ABSTRACT OF THE DISCLOSURE
A flowable material from which plaster, coverings, cladding or shaped articles can be obtained, comprises a mixture of:
a finely-particulate base material from clay tiles fired at below 1000°C;
a hydraulic binder; and a particulate inorganic insulating foam material.
These components may be mixed by the manufacture or by the user, on site, and formulated into a slurry.
A flowable material from which plaster, coverings, cladding or shaped articles can be obtained, comprises a mixture of:
a finely-particulate base material from clay tiles fired at below 1000°C;
a hydraulic binder; and a particulate inorganic insulating foam material.
These components may be mixed by the manufacture or by the user, on site, and formulated into a slurry.
Description
2~9~
Field of the Invention This invention relates to a flowable building material for the production of plaster, coverings, claddings and shaped articles, and to its use.
Background of the Invention Rough floor, wall and ceiling surfaces, and also pillars, columns, arches and cappiny plates, are usually provided with what may generally be termed a covering, e.g.
a cladding and/or plas~er. The covering removes unevenness, enhances the appearance of the structure, and protects the structure and its occupants against the harmful effects of weather, heat, cold, noise and the like.
The skilled man is familiar with the application of such coverings, e.g. the laying of panels or the application of superimposed layers of plaster. Panels may be of any shape. On a building site, however, shaped ar~icles such as stairs or window mouldings are used without covering.
Swiss Patent No. 675874 discloses a process for producing building materials for coverings, claddings and plaster, which have a porous structure providing the ability to breathe. Such porous building materials are inexpensive, yet the environmental load is positive because substantially natural starting materials may be used. The material comprises a finely-particulate base material from clay tiles fired at below 1000C; the base material is slurried with water, a hydraulic binder is added, and the damp mass is charged into a mould or is applied in layers to a substrate and allowed to dry.
An object of the present invention is to provide improved heat and sound insulating properties, while still using a material having a positive environmental load.
Summary of the Invention A novel flowable material, from which plaster, coverings, cladding or shaped articles can be obtained, comprises a mixture of:
2~6~
a finely-particulate base material from clay tiles fired at below 1000C;
a hydraulic binder; and a particulate inorganic insulating foam material.
Description of the Invention Depending on the user's requirements, the material may be supplied in the Eorm of a ready-made mixture, or the components may be mixed on site. The building material may therefore be stored and transported in the absence of water.
Without water, the material is a free-flowing dry mixture. Water may be added to form a slurry. Depending on the quantity of water added, the material remains pourable, becomes pourable and free-flowing or, as the proportion of water increases, merely free-flowing, without the formation of a cone.
The user of plaster, coverings or claddings which are applied in sltu to a rough building structure as a moist mass may obtain the required building material ready-mixed, and reduce it to a slurry with the necessary quantity of water. Alternatively, the individual components are obtained and charged, in the appropriate proportions, into a mixer, wherein a slurry can be formed by the addition of water to the fine-grained base material or to the prepared mixture.
Coverings can be converted with a suitable article to panels or plate moc~-ups, in that ~oints are drawn with this article.
The manuacturer of many and various shaped articles, from simple plates to individually-moulded panels which are several square metres in size and complicated window mouldings, may do so in a production plantO The building material can be prepared in a large mixer with a programmed procedure and automated addition of components, wherein the water for producing the free-~lowing mass can be added to the base material or to the prepared mixture. This mass is 2 ~ 3 g charged into moulds and sets by drying. The shaped articles can also be produced in presses.
It is of considerable importance for the building material that the base material consists essentially of clay tiles which have a porous structure and are fired at a low temperature, i.e. below 1000C. This base material exists after the tile-firing process, so the building material is produced without firing, only by setting.
The remains of wall and roof tiles frequently found on a building site and in the corresponding industrial processes can be ground to the desired grain size, which is preferably up to 0.5 mm, with relatively low outlay of energy and labour. The base material can also be produced from clay tiles obtained by demolition, without the jointing material having to be removed. Thus, for example, old chimneys can be put to an ecologically-useful and economically-worthwhile use.
Base material is also found as ground waste, cut waste and/or sawn waste from clay tiles, preferably having a grain size of less than O.S mm. During the cutting of plates, for example in accordance with Swiss Patent No.
659102, the contents of which are incorporated by reference herein, clay tile dust is produced in a large quantity as a viscous slurry from which the excess water can be removed after it has been left to stand~
Granular tile scrap, preferably having a grain size of 0.1 to 3 mm, can be added to the building material, in particular for decorative reasons. The colour of the tile scrap can match that of the base material but it is preferable to select at least one other, in particular a contrasting, colour. By using the tile scrap, it is possible to produce structures by grinding from surfaces produced with the building material, these structures including the grains of tile scrap in addition to the basic colour imparted by the base material.
The hydraulic binder is preferably cement, in particular white cement. The water moistened binder 2 ~ ~3~ ~
solidifies automatically and is water-resistant after setting. In this way, a clay-containing base material obtained from waste materials can be set without being refired. The hydraulic binder can be mixed with the other components in any ratio known to a person skilled in the art. The ratio of base material to hydraulic binder can be, for example, 3:1.
White cement is not only the highest quality binder, it is al50 preferred for ecological reasons. Furthermore, a lighter-coloured building material, which is usually desired, is formed when using white cement.
When the building material according to the invention is applied as a moist plastering composition, lime is suitable as the only or additional hydraulic binder.
However, the lime content is preferably kept low because it is heavier than the substituted clay-containing base material, and more readily leads to shrinkage cracks.
The particulate foam material that is used according to the invention can absorb a little water, but this is quickly removed from the base material and any sawn waste and the like. Owing to its porous structure, the foam material is capable of providing an unexpectedly high thermal and acoustic insulating effect which, overall, considerably improves the corresponding properties of the plaster, coverings, claddings and shaped articles produced with the building material.
Experiments have shown tha~ the foam material has a more advantageous effect, the finer its grains. The grain size is preferably 0.01 to 8 mm, more preferably 1 to 5 mm.
To apply especially effective sound-absorbing plasters, for example, a fraction of foamed grains having a grain size of 6 to 8 mm can be added to a finer-grained foam material, e.g. 0.01 to 2 mm in size. After application, the coarse particles can be at least partially worked out of the plaster by cross-wise sweeping with a lath or the like: a very rough surface is formed, which has very good sound-absorption properties.
The foam material is preferably foam glass which is produced, for example, from old glass by foaming and then 2 ~
shattering it. However, porous volcanic rock such as pumice or tufa, for example, as well as foamed ceramic material, can be incorporated into the building material quite generally as a foam material, in addition to or instead of foam glass.
Suitable optional components for increasing the porosity of the building material, used individually or together, include:
sawdust as a waste product of the timber industry, if a soft cladding which is a good insulator is to be produced:
shreds of paper, crushed or beaten old paper;
other natural fibres having an organic basis, such as cotton waste or flax fibres which also act as 5 reinforcing fibres; and rock wool.
Filter dust from glass, wood, textile, fibre cement, or paper-processing plant is important as a further additional component, used individually or together, for the building material. On the one hand, Pilter residues can be removed with the building material; on the other hand, waste materials can be put to a worthwhile use.
In summary, a building material according to the invention makes it possible to produce, in an inexpensive and simple manner, plaster, coverings, claddings and shaped articles which offer greatly increased heat and sound insulation, allow worthwhile utilisation of waste materials and offer an aesthetically satisfactory variation in appearance. The utilisation of waste obviously saves natural resources and prevents rapid filling of pits as well as vehicles.
The building material which is slurried with water to a moist free-flowing mass can also be used according to the invention specifically for the industrial manufacture of pressed and/or large shaped articles in addition to ~he above-mentioned use for the production of plaster, coverings claddings and shaped articles. Large shaped articles include, for example, kitchen ceilings.
Field of the Invention This invention relates to a flowable building material for the production of plaster, coverings, claddings and shaped articles, and to its use.
Background of the Invention Rough floor, wall and ceiling surfaces, and also pillars, columns, arches and cappiny plates, are usually provided with what may generally be termed a covering, e.g.
a cladding and/or plas~er. The covering removes unevenness, enhances the appearance of the structure, and protects the structure and its occupants against the harmful effects of weather, heat, cold, noise and the like.
The skilled man is familiar with the application of such coverings, e.g. the laying of panels or the application of superimposed layers of plaster. Panels may be of any shape. On a building site, however, shaped ar~icles such as stairs or window mouldings are used without covering.
Swiss Patent No. 675874 discloses a process for producing building materials for coverings, claddings and plaster, which have a porous structure providing the ability to breathe. Such porous building materials are inexpensive, yet the environmental load is positive because substantially natural starting materials may be used. The material comprises a finely-particulate base material from clay tiles fired at below 1000C; the base material is slurried with water, a hydraulic binder is added, and the damp mass is charged into a mould or is applied in layers to a substrate and allowed to dry.
An object of the present invention is to provide improved heat and sound insulating properties, while still using a material having a positive environmental load.
Summary of the Invention A novel flowable material, from which plaster, coverings, cladding or shaped articles can be obtained, comprises a mixture of:
2~6~
a finely-particulate base material from clay tiles fired at below 1000C;
a hydraulic binder; and a particulate inorganic insulating foam material.
Description of the Invention Depending on the user's requirements, the material may be supplied in the Eorm of a ready-made mixture, or the components may be mixed on site. The building material may therefore be stored and transported in the absence of water.
Without water, the material is a free-flowing dry mixture. Water may be added to form a slurry. Depending on the quantity of water added, the material remains pourable, becomes pourable and free-flowing or, as the proportion of water increases, merely free-flowing, without the formation of a cone.
The user of plaster, coverings or claddings which are applied in sltu to a rough building structure as a moist mass may obtain the required building material ready-mixed, and reduce it to a slurry with the necessary quantity of water. Alternatively, the individual components are obtained and charged, in the appropriate proportions, into a mixer, wherein a slurry can be formed by the addition of water to the fine-grained base material or to the prepared mixture.
Coverings can be converted with a suitable article to panels or plate moc~-ups, in that ~oints are drawn with this article.
The manuacturer of many and various shaped articles, from simple plates to individually-moulded panels which are several square metres in size and complicated window mouldings, may do so in a production plantO The building material can be prepared in a large mixer with a programmed procedure and automated addition of components, wherein the water for producing the free-~lowing mass can be added to the base material or to the prepared mixture. This mass is 2 ~ 3 g charged into moulds and sets by drying. The shaped articles can also be produced in presses.
It is of considerable importance for the building material that the base material consists essentially of clay tiles which have a porous structure and are fired at a low temperature, i.e. below 1000C. This base material exists after the tile-firing process, so the building material is produced without firing, only by setting.
The remains of wall and roof tiles frequently found on a building site and in the corresponding industrial processes can be ground to the desired grain size, which is preferably up to 0.5 mm, with relatively low outlay of energy and labour. The base material can also be produced from clay tiles obtained by demolition, without the jointing material having to be removed. Thus, for example, old chimneys can be put to an ecologically-useful and economically-worthwhile use.
Base material is also found as ground waste, cut waste and/or sawn waste from clay tiles, preferably having a grain size of less than O.S mm. During the cutting of plates, for example in accordance with Swiss Patent No.
659102, the contents of which are incorporated by reference herein, clay tile dust is produced in a large quantity as a viscous slurry from which the excess water can be removed after it has been left to stand~
Granular tile scrap, preferably having a grain size of 0.1 to 3 mm, can be added to the building material, in particular for decorative reasons. The colour of the tile scrap can match that of the base material but it is preferable to select at least one other, in particular a contrasting, colour. By using the tile scrap, it is possible to produce structures by grinding from surfaces produced with the building material, these structures including the grains of tile scrap in addition to the basic colour imparted by the base material.
The hydraulic binder is preferably cement, in particular white cement. The water moistened binder 2 ~ ~3~ ~
solidifies automatically and is water-resistant after setting. In this way, a clay-containing base material obtained from waste materials can be set without being refired. The hydraulic binder can be mixed with the other components in any ratio known to a person skilled in the art. The ratio of base material to hydraulic binder can be, for example, 3:1.
White cement is not only the highest quality binder, it is al50 preferred for ecological reasons. Furthermore, a lighter-coloured building material, which is usually desired, is formed when using white cement.
When the building material according to the invention is applied as a moist plastering composition, lime is suitable as the only or additional hydraulic binder.
However, the lime content is preferably kept low because it is heavier than the substituted clay-containing base material, and more readily leads to shrinkage cracks.
The particulate foam material that is used according to the invention can absorb a little water, but this is quickly removed from the base material and any sawn waste and the like. Owing to its porous structure, the foam material is capable of providing an unexpectedly high thermal and acoustic insulating effect which, overall, considerably improves the corresponding properties of the plaster, coverings, claddings and shaped articles produced with the building material.
Experiments have shown tha~ the foam material has a more advantageous effect, the finer its grains. The grain size is preferably 0.01 to 8 mm, more preferably 1 to 5 mm.
To apply especially effective sound-absorbing plasters, for example, a fraction of foamed grains having a grain size of 6 to 8 mm can be added to a finer-grained foam material, e.g. 0.01 to 2 mm in size. After application, the coarse particles can be at least partially worked out of the plaster by cross-wise sweeping with a lath or the like: a very rough surface is formed, which has very good sound-absorption properties.
The foam material is preferably foam glass which is produced, for example, from old glass by foaming and then 2 ~
shattering it. However, porous volcanic rock such as pumice or tufa, for example, as well as foamed ceramic material, can be incorporated into the building material quite generally as a foam material, in addition to or instead of foam glass.
Suitable optional components for increasing the porosity of the building material, used individually or together, include:
sawdust as a waste product of the timber industry, if a soft cladding which is a good insulator is to be produced:
shreds of paper, crushed or beaten old paper;
other natural fibres having an organic basis, such as cotton waste or flax fibres which also act as 5 reinforcing fibres; and rock wool.
Filter dust from glass, wood, textile, fibre cement, or paper-processing plant is important as a further additional component, used individually or together, for the building material. On the one hand, Pilter residues can be removed with the building material; on the other hand, waste materials can be put to a worthwhile use.
In summary, a building material according to the invention makes it possible to produce, in an inexpensive and simple manner, plaster, coverings, claddings and shaped articles which offer greatly increased heat and sound insulation, allow worthwhile utilisation of waste materials and offer an aesthetically satisfactory variation in appearance. The utilisation of waste obviously saves natural resources and prevents rapid filling of pits as well as vehicles.
The building material which is slurried with water to a moist free-flowing mass can also be used according to the invention specifically for the industrial manufacture of pressed and/or large shaped articles in addition to ~he above-mentioned use for the production of plaster, coverings claddings and shaped articles. Large shaped articles include, for example, kitchen ceilings.
Claims (20)
1. A flowable material from which plaster, coverings, cladding or shaped articles can be obtained, which comprises a mixture of:
a finely-particulate base material from clay tiles fired at below 1000°C;
a hydraulic binder; and a particulate inorganic insulating foam material.
a finely-particulate base material from clay tiles fired at below 1000°C;
a hydraulic binder; and a particulate inorganic insulating foam material.
2. A material according claim 1, wherein the base material has a particle size of up to about 0.5 mm.
3. A material according to claim 1, which additionally comprises granular tile scrap having a grain size of 0.1 to 3 mm.
4. A material according to claim 1, which additionally comprises granular tile scrap of a colour different from the base material.
5. A material according to claim 1, wherein the hydraulic binder is selected from cement and lime.
6. A material according to claim 1, wherein the hydraulic binder is white cement.
7. A material according to claim 1, wherein the foam material has a particle size of 0.1 to 8 mm.
8. A material according to claim 1, wherein the foam material has a particle size of 1 to 5 mm.
9. A material according to claim 1, wherein the foam material comprises a mixture of fractions respectively having particles sizes of 6 to 8 mm and 0.01 to 2 mm.
10. A material according to claim 1, wherein the foam material is selected from glass, volcanic rock and ceramic materials.
11. A material according to claim 1, which additionally comprises one or more additional components selected from sawing waste, waste paper, rock wool and natural fibre.
12. A material according to claim 1, which additionally comprises dust from glass, wool, textile, fibre cement or paper processing
13. A material according to claim 1, which additionally comprises water, and which is in the form of an aqueous slurry.
14. A method for forming a shaped article from an aqueous slurry of a building material, wherein the slurry comprises a mixture of:
a finely-particulate base material from clay tiles fired at below 1000°C;
a hydraulic binder; and a particulate inorganic insulating foam material.
a finely-particulate base material from clay tiles fired at below 1000°C;
a hydraulic binder; and a particulate inorganic insulating foam material.
15. A method according claim 1, wherein the base material has a particle size of up to about 0.5 mm.
16. A method according to claim 1, wherein the slurry additionally comprises granular tile scrap of a colour different from the base material.
17. A method according to claim 1, wherein the hydraulic binder is white cement.
18. A method according to claim 1, wherein the foam material has a particle size of 0.1 to 8 mm.
19. A method according to claim 1, wherein the foam material is selected from glass, volcanic rock and ceramic materials.
20. A method according to claim 1, wherein the slurry additionally comprises dust from glass, wool, textile, fibre cement or paper processing.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CH3950/90A CH682829A5 (en) | 1990-12-13 | 1990-12-13 | Building materials. |
CH03950/90-7 | 1990-12-13 |
Publications (1)
Publication Number | Publication Date |
---|---|
CA2056909A1 true CA2056909A1 (en) | 1992-06-14 |
Family
ID=4266971
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CA 2056909 Abandoned CA2056909A1 (en) | 1990-12-13 | 1991-12-04 | Flowable building material |
Country Status (4)
Country | Link |
---|---|
EP (1) | EP0490813A1 (en) |
CA (1) | CA2056909A1 (en) |
CH (1) | CH682829A5 (en) |
HU (1) | HUT60351A (en) |
Families Citing this family (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CH685628A5 (en) * | 1992-12-30 | 1995-08-31 | Arnold Buechel | Building materials. |
DE4300894C2 (en) * | 1993-01-15 | 2002-11-21 | Rigips Gmbh | Dry plaster mix and process for making it |
DE4337777A1 (en) * | 1993-11-05 | 1995-05-11 | Dennert Poraver Gmbh | Plastering mortar with high thermal insulation capacity |
DE29506090U1 (en) * | 1995-04-07 | 1995-06-01 | Heilit & Woerner Bau Ag | Sound-absorbing covering on a continuous support plate of a track superstructure |
DE19540273A1 (en) * | 1995-10-28 | 1997-04-30 | Dennert Poraver Gmbh | Pumpable lightweight wall mortar, class LM 21 |
EP0983975A1 (en) * | 1998-09-03 | 2000-03-08 | Claudio Bricca | A process of making formed bodies consisting of crushed terracotta and a binder |
IT1309448B1 (en) * | 1999-06-21 | 2002-01-23 | Sannini Impruneta Spa | CONSTRUCTION MATERIAL BASED ON A COTTO AND CEMENT MIXTURE. |
RU2454383C1 (en) * | 2011-03-21 | 2012-06-27 | Юлия Алексеевна Щепочкина | Crude mixture for making construction articles |
DE102020118429A1 (en) | 2020-07-13 | 2022-01-13 | Alfred Oberender | building material mixture |
Family Cites Families (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB287363A (en) * | 1927-06-22 | 1928-03-22 | Louis Frederick Tooth | Improvements in compositions for heat insulating and heat resisting purposes |
FR1115932A (en) * | 1954-08-13 | 1956-05-02 | Compostion for building material, and its manufacturing process | |
CH440088A (en) * | 1966-01-06 | 1967-07-15 | Hofmann & Co E | Process for the production of components and component produced according to this process |
DE3608180A1 (en) * | 1985-03-13 | 1986-10-09 | Franz Felix 46509 Xanten Hopmann | Mixture for producing coatings and/or mouldings, in particular having a polished (ground) surface, for the building and construction industry |
CH675874A5 (en) * | 1988-08-11 | 1990-11-15 | Arnold Buechel |
-
1990
- 1990-12-13 CH CH3950/90A patent/CH682829A5/en not_active IP Right Cessation
-
1991
- 1991-12-03 EP EP19910810936 patent/EP0490813A1/en not_active Withdrawn
- 1991-12-04 CA CA 2056909 patent/CA2056909A1/en not_active Abandoned
- 1991-12-12 HU HU392591A patent/HUT60351A/en unknown
Also Published As
Publication number | Publication date |
---|---|
HUT60351A (en) | 1992-08-28 |
EP0490813A1 (en) | 1992-06-17 |
CH682829A5 (en) | 1993-11-30 |
HU913925D0 (en) | 1992-04-28 |
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Legal Events
Date | Code | Title | Description |
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FZDE | Dead |