VICROADS GUIDELINE

TCG 006B – 1 – 2003

The Installation
Of

Street Lighting
For

AS/NZS 3000 Street Lighting Schemes

(Including Amendment B)

Original Issue Date: December 2003

Amendment B: May 2010
TCG -006B-1-2003

TCG 006B-1-2003

Foreword

This guideline has been developed by VicRoads. It is one of a number

of technical specifications, and associated standard drawings, which set
out the requirements for roadside ITS devices, traffic signal equipment
and other electrical equipment and associated devices and control
systems.

This guideline is intended for use in all relevant works undertaken by or

on behalf of VicRoads.

VicRoads Standard Drawings, Specifications and Guidelines are

available for downloading from VicRoads website at the following
address under ‘Tenders & Supplier’:
http://www.vicroads.vic.gov.au/itsspecs

Guideline updates. VicRoads specifications and associated standard drawings

are subject to periodic review. To keep the specifications up to date,
amendments or new editions are issued as necessary. It is therefore important
for users of VicRoads specifications to ensure that they have the latest version
and associated amendments.

Road User Services

60 Denmark Street Kew 3101

Phone: (03) 9854 2103 Fax: (03) 9854 2319

COPYRIGHT

© Roads Corporation Amendments

trading as VicRoads. All Amendment No. B May 2010 Installation section removed from
rights reserved. Design section and reissued as
separate document.
This document remains the
property of VicRoads. No part of Clauses renumbered as required.
this document may be
reproduced or copied in any Obsolete sections updated and/or
form or by any means, electronic
removed.
or mechanical, including
photocopying, without the written
permission of VicRoads.

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 TCG 006B-1-2003

Contents

1. INSTALLATION ........................................................................................................................5
2. SCOPE.....................................................................................................................................5
3. SERVICES ...............................................................................................................................5
4. POLES .....................................................................................................................................5
4.1 Notice ...............................................................................................................................5
4.2 Installation of Joint Use Poles and Joint Use Mast Arms ...................................................6
4.3 Installation of Frangible (IA & SB) Poles............................................................................6
4.4 Torque ..............................................................................................................................7
4.5 Operating near Power Lines .............................................................................................8
5. LUMINAIRE ORIENTATION.....................................................................................................8
6. PITS .........................................................................................................................................8
7. CONCRETE .............................................................................................................................9
8. CONDUIT LOCATIONS............................................................................................................9
9. REDUNDANT ASSETS ............................................................................................................9
10. BACKFILLING, RE-INSTATEMENT AND CLEAN-UP WORKS ............................................9
10.1 Backfilling .........................................................................................................................9
10.2 Re-Instatement ...............................................................................................................11
10.3 Civil Works Clean-Up ......................................................................................................11
11. COMPLETION ....................................................................................................................11
11.1 Compliance.....................................................................................................................11
11.2 Testing and Certificate of Electrical Safety ......................................................................12
11.3 Warranty ........................................................................................................................12
11.4 Commissioning ...............................................................................................................13
12 ELECTRICAL .........................................................................................................................13
12.1 Wiring Rules ...................................................................................................................13
12.2 Registered Electrical Contractor......................................................................................13
12.3 Electrical Design .............................................................................................................13
12.4 Power Supply .................................................................................................................14
12.5 Distribution Company Assets ..........................................................................................15
12.6 Earthing Requirements ...................................................................................................15
12.7 Jointing ...........................................................................................................................15

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 TCG 006B-1-2003

1. INSTALLATION

New VicRoads stand-alone street lighting schemes shall be installed in accordance with AS/NZS
3000 and in accordance with the VicRoads Standard Specification for Roadworks and Bridgeworks.

2. SCOPE

The installation of a new street lighting scheme by the Contractor shall include:

a) Liaison with the local Distribution Company and relevant authorities for the installation
of the works, and the obtaining of all necessary approvals and permits from the relevant
authorities;

b) Supply and installation of all civil works including trenching, under road bores,
conduits, conduit bends, cable pits and lids, draw strings, slabs, distribution box
foundations, and pole foundations;

c) Supply, installation and connection of all hardware, equipment and materials including
the distribution box, poles, brackets, luminaires, electrical cables, cable guards, fuses,
fittings and all materials and equipment necessary to complete and commission the
street lighting installation; and

d) Re-instatement of all works.

3. SERVICES

The location of all existing underground and aboveground services shall be proven and
confirmed on site by the Contractor before commencement of any works.

Contractor liaison shall be undertaken with all relevant authorities, and the electrical
power Distribution Companies as necessary regarding the conduit locations, pit locations,
pole locations, and the point of power supply.

The Contractor shall make all necessary arrangements for the connection of power to the
distribution box(es).

4. POLES

4.1 Notice

Upon a minimum of sixty (60) days notice, and only where specifically required by the
installation contract, VicRoads shall supply free on ground all necessary joint use traffic signal
poles and joint use mast arm poles.

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4.2 Installation of Joint Use Poles and Joint Use Mast Arms

a) The Contractor shall carry out installation in accordance with VicRoads specification
numbered TCS013 for the Installation and Remodel of Traffic Signals. Refer also to
VicRoads specification numbered TCS001 for the Supply of Joint Use Poles, Joint Use
Mast Arms, Mast Arms, and Rigid Street Lighting Poles.

b) Distribution Company and appropriate HV transmission company current clearance

requirements shall be adhered to by the Contractor.

4.3 Installation of Frangible (IA & SB) Poles

Frangible poles shall be supplied by the Contractor, must be VicRoads type approved, and
shall conform to VicRoads frangible pole specification TCS014 and to drawings TC-1064
and TC-1065. These poles are to be transported to the site of the works in one piece with
the base section securely bolted to the upper section.

The Contractor shall install frangible poles in a vertical position +/- 2 degrees and in
accordance with AS/NZS 3000. The power supply to the frangible pole shall be fused in the
pit.

The Contractor shall install impact absorbing poles so that the joint between pole and base
shall be located at 75mm + or - 25mm above the finished ground surface level. The slip
plane of a slip base pole shall be located 75mm + or -25mm above the finished ground
surface level to allow proper movement of the pole if involved in a crash.

The Contractor shall backfill around the pole and reinstate the ground around the pit and pole.
Where a concrete mowing pad has been formed around the pole at ground level, the
Contractor shall ensure that the bolt heads are kept clear of the concrete.

The Contractor shall firmly attach the bracket to the pole spigot using the clamping bolt
assembly which is supplied with the bracket.

The Contractor shall use 2.5mm2 TPS cable (or 6mm2 supply cable with Superintendent’s
approval) within the pole from the cable termination access door to the limit of the bracket
arm. In an impact absorbing pole the cable shall be supplied through the flexible conduit
fitted inside the pole from the cable termination access door to the pole spigot, then continue
the cable to the limit of the bracket arm. If a double bracket arm is used, 1.5mm2 cable
shall be looped between the luminaires.

The Contractor shall align the bracket and luminaire as shown in the street lighting design
(this is usually, but not always, at right angles to the vehicle path on the road), and shall
install and plumb the pole and luminaire(s) to within the tolerances specified in Table 1 below.

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TABLE 1: Pole and Luminaire Orientation details

Pole Lantern Lantern Max Lantern Lantern Lantern

Height Mounting Lamp Bracket Angle to Upcast Spin
Height Size Length Road Angle Angle
SB/IA
Metres Metres Watts Metres Degrees Degrees Degrees

8.5 10.0 150 3.0 90 ± 5 5±1 0±1

11.0 12.5 250 5.0 90 ± 5 5±1 0±1

13.5 15.0 400 5.0 90 ± 5 5±1 0±1

NOTES: SB indicates Slip Base pole; IA indicates Impact Absorbing pole.
*There is no 13.5 metre variant of the Impact Absorbing pole.

4.4 Torque
AMDT
No. B The Contractor shall supply and install slip base poles in accordance with the following
May
2010
requirements:

a) the pole shall be installed such that the slip nut is placed in the upper position to
enable ease of access for correct torque installation and for subsequent annual torque
maintenance checking;

b) the slip bolts and nuts shall be re-run after galvanising and shall be free of excess
galvanising in the threads;

c) the thin slip plane washer shall be supplied flat and free of kinks, bends, deformation
and warping. A damaged slip plane washer can result in incorrect torque and
eventual pole failure and shall not be used; and

d) the slip-plane holding down nuts and bolts on the flange shall be torqued to 80Nm. The
slip-plane flange nuts shall then be slackened off ONE AT A TIME and re-tightened to
80Nm (59 ft lb) using an accurately calibrated torque wrench.

The Contractor shall supply and install slip base poles in accordance with the
following requirements:

e) The pole shall be installed such that the slip nuts are placed in the upper
position to enable ease of access for correct torque installation and for
subsequent annual torque maintenance checking;

f) The slip bolts and nuts shall be re-run after galvanising and shall be free of
excess galvanising in the threads;

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TCG -006B-1-2003

g) The thin slip plane washer shall be supplied flat and free of kinks, bends,
deformation and warping. A damaged slip plane washer can result in incorrect
torque and eventual pole failure and shall not be used; and

h) The slip-plane flange nuts shall then be slackened off ONE AT A TIME and re-
tightened as follows;

i. Fit an open-ended spanner to the half nut;

ii. Fit a ring spanner to the main nut;
iii. Remove the main nut;
iv. Fit a ring spanner to the bolt head;
v. Use a torque wrench and the ring spanner to tighten the half nut to a snug-
tight condition, so that all joint members are in contact with each other and
gaps are closed. Torque shall not exceed 40 Nm;
vi. With ring spanner still on bolt head, fit the open-ended spanner to the half nut;
vii. Hold both spanners while applying torque to the main nut;
viii. Tighten main nut to 90Nm.

For further information see Traffic Control Notice TCN-006.

4.5 Operating near Power Lines

In the installation or removal of poles, or working on poles, when operating plant, machinery, or
equipment near power lines the Contractor shall meet all relevant requirements of the Office of the
Chief Electrical Inspector and shall provide “Spotters” in accordance with the Inspector’s regulations.

The Contractor shall also meet the requirements of the VicRoads Safe Operating Practices “Plant
Operation in Proximity to Overhead power lines”, and “Plant contact with overhead powerlines”.

5. LUMINAIRE ORIENTATION

Unless otherwise designed, the Contractor shall install luminaires such that they meet the
mounting and orientation requirements of Table 2 above.

6. PITS

The Contractor shall install all cable pits and lids (TC-1210 and TC-1220) in accordance
with VicRoads standard drawing TC-1230 and with the approved detailed street lighting
design. The cable pit shall be located to minimise water ingress. The pit shall generally be
located 1 metre in advance of, and 1 metre off the line of, the pole. A 2 metre spare length of
each cable shall be left coiled in the pit.

All conduit shall be installed complete with draw string and shall terminate in cable pits.
The ends of the conduits shall be blocked to prevent the ingress of dirt.

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 TCG 006B-1-2003

Not withstanding the requirements of AS/NZS3000, installation, bedding and backfilling of

conduits, pits and trenches shall be carried out in accordance with VicRoads standard
drawings and in accordance with section 733 of the VicRoads Standard Specification.

7. CONCRETE

The Contractor shall install all concrete works in accordance with VicRoads standard
drawings and in accordance with sections 610, 611, and 614 of the VicRoads Standard
Specification.

8. CONDUIT LOCATIONS

Detailed recording is required of the actual installed conduit locations. The Contractor shall
accurately depict the actual installed conduit locations on A3 size MicroStation CADD drawings of the
lighting scheme and road layout.

The Contractor shall supply to the Superintendent two copies of each drawing along with a CD or
3.5 inch 1.44mb capacity floppy disks containing the CADD drawing files, and the same shall be
supplied by the Contractor to the local Distribution Company if appropriate.

9. REDUNDANT ASSETS

As existing public lighting assets may be owned by the local Distribution Company, the
Contractor shall give consideration to the method of removal of redundant lighting assets
and, where required, shall deliver such redundant assets to a location specified by that
Distribution Company within its area.

10. BACKFILLING, RE-INSTATEMENT AND CLEAN-UP WORKS

The Contractor shall comply with the requirements of the Road Opening Permit issued by the
Highway Authority. Where these requirements are silent, the following requirements are to be
complied with.

10.1 Backfilling

(a) Material

AMDT All materials used for backfilling shall be free from perishable matter and shall, unless otherwise
No. B
May specified or approved by the Superintendent, conform with the appropriate grading requirements of
2010 Table 733.071 733.061 given in Section 733.07 733.06 Backfilling of the VicRoads Standard
Specification for Roadworks and Bridgeworks.

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TCG -006B-1-2003

Road pavement material shall consist of crushed rock complying with the relevant requirements
of the VicRoads Standard Specification for Roadworks and Bridgeworks, unless otherwise specified
or approved by the Superintendent.

Section 812 - Crushed Rock and Plant Mixed Wet-Mix, Crushed Rock for
Base and Sub-base Pavement; and

Section 815 - Cement Treated Crushed Rock for Sub-base Pavement.

Backfill under road pavement shall conform with the requirements of the table below:

Depth below finished surface Material

Temporary Surfacing 100mm premix asphalt

Upper Pavement Level To 500mm below FSL Class 2A FCR

Lower Pavement Level To 500mm from FSL FCR max PI 15

FSL - finished surface level. FCR - fine crushed rock. PI - plasticity index

(b) Filling

Selected and ordinary backfill shall be placed and compacted as follows, under, around and
above the conduit after the sections are bedded, unless otherwise specified or approved by the
Superintendent:

1. Conduits not under Roads

The trench shall be backfilled with selected backfill material to a level of 400mm
above the top of the conduit and with ordinary backfill above that level to a level
50mm below the surrounding surface.

2. Conduits under Existing Roads

The trench shall be backfilled to the existing subgrade level with selected backfill
material and the road restored using approved materials, unless otherwise specified
by the Superintendent.

(c) Compaction

Backfilling shall be compacted in such a manner so as to result in a settlement of the

finished surface of not more than 10mm after 6 months.

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 TCG 006B-1-2003

10.2 Re-Instatement

All completed areas of excavation are to be reinstated or made safe in accordance with
these procedures before the Contractor leaves the site at the end of each working day.

On completion, the Contractor is to ensure that all excavation is back filled, smoothed out,
and levelled.

The Contractor is to reinstate all trenched and excavated areas with crushed rock or
backfill material.

In paved areas, other than under road pavement, the top 50mm shall be compacted
pre-mixed asphalt, finished to match the level of the surrounding paved or road areas.
Any subsequent reinstatement due to subsidence will be at the Contractor's cost.

In non-paved or grassed areas the top 50mm of backfill material is to be of selected

material from the site of the same soil composition as the original surface material, or
material of a type approved by the Superintendent as suitable, i.e., topsoil.

All disturbed areas are to be reinstated by the Contractor to the level and standard of
finish before work started. This requires that a grassed area will be replaced with topsoil, and
suitable grass seed is to be sown and watered in. A concrete area will be saw cut and re-
concreted, a landscaped area will be re-landscaped, and any other will be replaced to its
original state.

10.3 Civil Works Clean-Up

On completion of all excavation and reinstatement works, the Contractor is to ensure that
all rubble, surplus crushed rock, surplus pavement materials, surplus concrete and all other
surplus materials are removed from the site. The Contractor is to leave the work site in a
clean and safe condition.

Subject to section 6.8 above, civil hardware and equipment which is not to be re-used or
salvaged is to be removed from the site and disposed of by the Contractor and the cost of
removal and disposal is to be included in the tender price.

11. COMPLETION

11.1 Compliance

Following implementation of the installation phase of a stand-alone street lighting scheme

under this guideline, the Contractor shall:

• Check and adjust luminaire orientation as required;

• Replace all luminaires containing PE cells, or with the approval of theSuperintendent, bypass
the PE cells in the luminaires;

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 TCG -006B-1-2003

• Replace all damaged or non-functional luminaires, ballasts, and external igniters;

• Check all brackets for type, size, shape and tolerance and replace where not in conformance
with the VicRoads standard drawings and within the specified tolerance limits;

• Check and adjust all brackets for fixing and for orientation;

• Inspect all joint use poles and joint use mast arms for proper installation and functioning, and
rectify all faults;

• Check all lighting poles for type, size, location, orientation, bolt washers, bolt torque, slip plane
washer, verticality, and ground clearance, and where not in compliance replace, adjust or
reinstall as appropriate;

• Inspect all pits, conduits, cables, and all other components, and where faulty repair or replace
as necessary;

• Check all electrical circuitry, materials, components, and equipment for conformance with
AS/NZS 3000, and rectify where full compliance has not been achieved; and

• Check all distribution boxes for correct installation and rectify as necessary. The distribution
box shall be inspected and tested for faults and non-complying components. The lumatrol and
switching gear shall be tested and replaced if found to be faulty or performing unsatisfactorily.
A copy of the street lighting wiring diagram shall be prominently displayed in the distribution
box.

One week before practical completion on the Whole of the Works, or as otherwise determined by the
Supervisor, the torque in the slip base pole slip plane holding down nuts and bolts on the flange
shall be checked by the Contractor with an accurately calibrated torque wrench, and the nuts shall
be adjusted as required, in accordance with the guidelines.

11.2 Testing and Certificate of Electrical Safety

Prior to final acceptance, the Contractor shall test all distribution boxes, circuits,
switches, lumatrols, luminaires, and all other electrical and electronic components for
correct installation and operation.

The Contractor shall be responsible for arranging for the issuing of a Certificate of Electrical
Safety for the scheme. The Superintendent may not accept the installation of the scheme
as complete until such time as the Certificate of Electrical Safety has been duly issued.

AMDT 11.3 Warranty

No. B
May
2010 The installation contractor shall provide a warranty for all contractor supplied and installed street
lighting system components for a period equal to the defects liability period for the contract.

This warranty shall also expressly include the replacement of any and all lamp failures occurring
within the defects liability period.

If the Distribution Company is the installation contractor, the warranty is still required.
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 TCG 006B-1-2003

Note that this warranty obviates the need for additional and separate maintenance for
normal wear and tear for the new lighting scheme for the full defects liability period, excepting crash
damage.

11.4 Commissioning

Upon final acceptance, the Contractor shall switch on the lighting scheme at the distribution
box in automatic mode, and record the time, date and meter reading for contractual, warranty
and power supply purposes.

12 ELECTRICAL

12.1 Wiring Rules

AMDT
No. B
All electrical works, electrical fittings, materials and installations shall fully conform to the
May requirements of the latest edition of AS/NZS 3000:2000 Electrical Installations (Australian /
2010
New Zealand Wiring Rules).

AMDT Where AS/NZS 3000:2000 does not cover a specific aspect of the electrical works (eg.
No. B
May such as pits) all works shall be undertaken in conformance to the requirements of the Office
2010
of the Chief Electrical Inspector.

12.2 Registered Electrical Contractor

The electrical Contractor engaged to carry out electrical works on any VicRoads street lighting
scheme shall be a Registered Electrical Contractor, being registered in accordance with:

a) Part 3 of the Electricity Safety Act 1998; and

AMDT
No. B
May b) Electricity Safety (Installations) Regulations 1999 Contractors.
2010

The electrical Contractor shall also be pre-qualified in the VicRoads categories of "On-Road Electrical
Installation and Maintenance" to undertake street lighting works.

12.3 Electrical Design

The electrical design for the supply of 240 v AC electrical power from the meter in the
distribution box to all luminaires shall be approved by a suitably qualified electrical engineer.

The electrical design shall include all electrical circuits, cabinets and switch gear including
determination of power supply points from the appropriate Distribution Company. The
installation contractor shall be responsible for obtaining all necessary approvals from the local
Distribution Company.

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 TCG -006B-1-2003

The electrical control system is to be such that VicRoads lighting for each scheme shall
be switched instantaneously using a photo electric switch.

An independent electrical circuit(s) shall be provided to cater for all of the VicRoads
lighting. The electricity supply shall be metered to the VicRoads electrical circuit(s).

Where practicable, all above ground electrical installations and works, such as point of
power supply and the distribution box, shall be located a minimum of 10m from any
carriageway.

12.4 Power Supply

Unless otherwise approved by the Superintendent, the supply of electricity shall be in accordance with
the following:

a) The "Point of Supply" shall be determined in conjunction with the relevant Distribution
Company. The supply of electrical power from the point of supply to the meter in the
distribution box shall be in accordance with the requirements of the relevant Distribution
Company.

b) The electricity supply shall be 240 volt three phase AC power supply. Single phase
power may only be supplied with the prior written approval of the Superintendent. The
low voltage power supplies shall be strategically placed to minimise the maximum
load on each lighting circuit and to limit the extent of voltage drop.

c) In accordance with the wiring design, copper consumer mains cable shall be
AMDT
No. B
provided in underground conduit to the base of each LV supply point pole
May mechanically protected to 2.4 metres above ground level (on the pole) with 6 metres
2010
tail to Distribution Company requirements for final termination by the Distribution
Company into a 3 phase, 100 amp, Fused Mains Box, 4 metres above ground in
accordance with the Victorian Service & Installation Rules (December 1999)
(SIRs).See Figures 5.1, 5.2, and 5.10 of the SIRs.

The cable for trunk electricity supply from the "point of supply" to the street lighting
distribution box or the appropriate street lighting power supply pit (where no
distribution box is installed) as appropriate, shall be not less than 16mm square 4 core
three phase Copper orange circular cable.

d) The required conduits for power supply shall be installed in accordance with
AS/NZS3000, and with the requirements of the relevant Distribution Company for
underground power supply.

The conduits for trunk electricity supply from the "point of supply" to the street lighting
distribution box or the appropriate street lighting power supply pit (where no
distribution box is installed) as appropriate, shall be 63mm Dia heavy duty grade
non-metallic rigid orange UPVC to AS 2053.2-1995 and to Distribution Company
requirements.

Power supply conduits shall be located at least 1200mm below the finished
surface of any freeway, State highway, main road, or tourists' road.
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 TCG 006B-1-2003

e) It shall be the responsibility of the installation contractor to lodge all notices, pay all
fees and arrange all inspections.

12.5 Distribution Company Assets

The use of Distribution Company poles for any purpose other than obtaining power supply shall
be avoided everywhere possible. Where it is necessary to mount VicRoads street lighting assets on
Distribution Company poles the luminaires shall not be connected to any VicRoads power circuit.

12.6 Earthing Requirements

An earth stake shall be installed in the 50mm conduit in the concrete base of the distribution box as
shown on VicRoads drawing TC-1062.

AMDT An earth cable shall be installed in all VicRoads lighting circuits from the distribution box. All
No. B
May earths shall be terminated within the lighting distribution box in accordance with Wiring Rules AS/NZS
2010 3000:2000 Electrical Installations for the M.E.N. (multiple earth neutral) system of earthing.

Where necessary, and in accordance with the wiring design, a separate PVC insulated and
sheathed earth cable shall be provided to ensure compliance with AS/NZS3000.

All poles shall be individually earthed to the earth cable in the pit in the case of frangible poles and to
the earth cable in the pole in the case of rigid poles.

All luminaires shall be individually earthed.

AMDT The size of earth cable is to be designed to ensure a Fault Loop Impedance “low enough to allow
No. B
May sufficient current to flow in the fault loop to cause the protective device to operate within the
2010 disconnection time” in accordance with AS/NZS3000:2000 Clause B4.2.

12.7 Jointing

All electrical cable joints in pits shall be waterproofed.

An appropriate size junction box to not less than IP56 shall be provided for cable terminations
in pits. The cables shall be fitted into the junction box through glands and all connections
shall be securely tightened. After completion, the whole assembly shall be completely filled
with an electrical epoxy insulating resin in order to produce a waterproof joint. All
connectors shall be completely covered.

No foreign matter or filler of any type, such as sand, shall be introduced into the insulating
resin in the junction box.
AMDT
No. B
May Alternative forms of jointing may be allowed with approval.
2010

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