2.3.2. CUBIERTAS SYSTEM THE Code - TYPE OF Marzo 2013 Date

CORPORATE COUNTRY

HEADLINE ON ELEMENTOS DECORATIVOS TWODUCTAL LINES (UHPC) CON Efficient Building System

Date

©Ashford Brown –Jean-Michel Labat & Philippe Caron

CONTENTS Page 1. Introduction

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2. Reference projects

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3. Technical description

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4. System performances

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5. On-site implementation

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6. Environmental performances

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7. Contributions to buildings and cities

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8. Related information

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GLOSSARY     

DUCTAL® : a family of Ultra-High Performance Concrete (UHPC) products that provide a unique combination of strength, ductility, durability, and aesthetics, allowing architects and engineers to create innovative, sustainable designs. DUCTAL® FM: structural applications DUCTAL® AF: structural applications with specific resistance to fire requirements DUCTAL® FO: specially designed for elements that require aesthetically pleasant appearances UHPC: Ultra High Performance Concrete.

This system contributes to creating buildings that are Long lasting Robust Responsive Transparent Easy to Build and cities characterized by Adaptability Continuity Preparation Diversity For more information, Please see section 8.

APPLICATIONS  Building sectors: Recreational, commercial, industrial. offices and public buildings (health and education), residential (individual housing, collective housing, high rise buildings) and transport infrastructure.  Both new construction and renovation work  Precast applications  Limits: (check structural, or dimensional limits)

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LIGHT AESTHETIC UHPC ROOF

1. Introduction Light Aesthetic UHPC Roofs Light Aesthetic UHPC Roofs with Ductal® provide solutions for specific structural and aesthetic designs. UHPC Ductal® allows the construction of concrete roofs with almost no reinforcement, blending slim elements and complex profiles, offering design versatility with nearly endless array of colors and textures, watertight seals and exceptional durability making it ideal for roof applications. There are many design applications for light aesthetic UHPC roofs which include thin shell canopy structures, cantilevers, and one way precast slab construction with perforations for skylights. The material’s closed microstructure makes it nearly impermeable to water, it is totally waterproof when designed with the thickness of over10mm ( according to CSTB test) making it possible to design shell roof structures which are untreated. All systems are precast and thus are easily and quickly installed on site.

Advantages  

Possibilities of extremely thin, complex architectural forms Lightweight perforated structures

p.8 p.8

> Incorporation of glass in perforation for light filtration > watertight seals

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Architectural surfaces > Colour, texture and superior surface finish

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p.9

Exceptional durability and extended life span > Resistance to fire, corrosion and abrasion

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p.9

ROOF

2. Reference projects ©Ashford Brown –Jean-Michel Labat & Philippe Caron

WELEDA PHARMACEUTICAL LABORATORY  Location: >

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Building function: >

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Maryam Ashford-Brown

Building owner/client: >

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2010

Architect: >

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Headquaters of Weleda Laboratories.

Year of construction: >

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Huningue, Alsace, France

Weleda

Additional information on the project:

Perforated roof providing fire resistance. Ductal® AF (Anti-fire) slabs 2.5mx 12.75m to 6cm overall thickness rib, total area- 3285 m2

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1. Ductal® AF precast 2. 120mm Roof Insulation 3. Double glassed sky light

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©Ashford Brown –Jean-Michel Labat & Philippe Caron

Ductal® allowed the fabrication of perforated roof slabs with a very high slenderness ratio giving architects the possibility to make irregular skylights without the need for the steel reinforcement. These openings in the roof create a comfortable occupancy in the building flooding it with natural light.

Designing with Ductal® concrete UHPC Ductal® was used for the construction of the roof for the foyer of the building. The roof is perforated and protected with lowemission glazing to reduce the heat loss. The strength of Ductal® allowed the creation of the ribbed slabs of less than 6cm thickness for span of 12.75m without reinforcement that is not possible with conventional concrete. The roof is painted a vibrant white.

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©Lafarge

Why Ductal®?

ROOF ©Lafarge

VILLA NAVARRA 

Location: >

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Building function: >

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Rudy Ricciotti

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Rudy Ricciotti

Engineer:

>

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Private Art Gallery

Year of construction: > 2008 Architect:

>



Var, France

LR Ingéniérie

Building owner/client:

>

Enrico Navarra

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Additional information on the project: The cantilevered roof of 7.8m is comprised of seventeen 9.25m x 2.35m panels, each weighing approximately 3 tonnes. Ductal® is used 100% structurally for flexion in the ribbing. The panels rest on two strip footings.

©Leon Grosse, Rudy Ricciotti

©Leon Grosse, Rudy Ricciotti

Why Ductal®?

Designing with Ductal® concrete

With Ductal®‘s unique properties the creation of thin and complex structures are made possible. Ductal® offers a superior strength, high durability and aesthetic design flexibility. Ductal® was specifically chosen for the construction of a roof for this project. With a 7.8 m overhang and very thin panel thickness in the unribbed sections. The overhang frees the building façade from any structural element, allowing the installation of a windowed façade without upper support. The selection Ductal® concrete for construction also makes the building watertight.

Ductal®‘ is an ultra-high performance, fiber reinforced material that provides exceptional durability without compromising design aesthetics. Ductal®‘ allows the ability to create innovative designs with new shapes that are thinner, lighter and more graceful compared to conventional concrete. Ductal® specifically chosen for the design of the roof of this project as the roof structure is proportioned in relation to its own weight, wind lift, thermal expansion and service load, is delivered as is without needing any waterproofing.

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©Lafarge

©Lafarge

JEAN BOUIN STADIUM, PARIS Perforated Roof Structure – Waterproofing via Glass   

©Leon Grosse, Rudy Ricciotti

  

Location: > Paris, France Building function: > Rugby Stadium. Year of construction: > 2013 Architect: > Rudy Ricciotti Building owner/client: > City of Paris Additional information:

The 23,000m2 envelope, including a 12,000m2 roof is made of 3600 self supporting triangle elements. The Lattice mesh triangular shapes made from Ductal®, are each 8m to 9m long by 2.5m wide and 4.5cm thick.

Illustrating an innovative design of a Lattice roof element achieved with Ductal® allowing an incorporation of waterproofing via glass

Roof structure –waterproofing via glass Each section of the roof incorporates the primary and secondary structures, drainage of water, the architectural skin and most importantly the waterproofing via glass that is incorporated during pouring of lattice roof elements. Out of a 23,000m2 concrete envelope of the stadium, the 12,000m2 is the roof structure consisting of 1,900 mesh triangular elements made out of Ductal. ©Leon Grosse, Rudy Ricciotti

Why Ductal®?

Designing with Ductal® concrete

The use of a single material Ductal®, allowed greater durability, fewer joints with intermediate parts to be covered, less implementation time and greater safety since all the construction elements are manufactured in a workshop. The panels on the façade form light and porous web, the roof design is simple to allow spaces for protective and light-diffusing glass for waterproofing purposes. Ductal® allowed the fabrication of perforated panels with a high slenderness ratio. The absence of reinforcing steel in the Ductal® permits more perforation and long spans up to 9m long.

The design of the stadium’s envelope is asymmetric. The only way to achieve asymmetry and to create two curves was to use a triangular shape mesh elements. An Ultra -High Performance Concrete Ductal® was used, to create triangular mesh shapes. Designing with Ductal® concrete benefits economic performance and environmental performance of the construction. The construction was compacted, the designers used fewer materials and less primary energy.

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LIGHT AESTHETIC UHPC ROOF

3. Technical description

GENERAL DESCRIPTION OF THE SYSTEM  Ductal® Concrete Roofs without reinforcement The properties of Ductal® offer superior flexibility of design for building systems that combine slim elements with long spans, making it ideal for the construction of concrete roofs. There are variety of possibilities of designing concrete roofs with UHPC Ductal® and creation of different types of forms and surfaces: • Flat plain surface roof • Perforated roof designs • Perforated roofs with glass incorporation Lightweight concrete roofs are possible with Ductal® due to material’s properties, the superior combination of strength and ductility. The roof structure can be slender, lightweight, have slim elements, and tight seals, which offers superior durability without the need of reinforcement. In addition, the system is able to carry large loads without risk of sudden failure. Designing with a possibility of low number of reinforcement leaves architects and designers the complete freedom to design and imagine new geometries that would otherwise be unfeasible. Ductal® concrete is designed specific to application: • Ductal® FM (Fiber Metallic) designed for structural applications • Ductal® AF (Anti-fire) is designed for structural applications with specific resistance to fire requirements. • Ductal® FO (Fiber Organic) specifically designed for elements that require aesthetically pleasant appearances

Ductal® is an ultra-high performance concrete with combination of unique properties such as strength, durability, ductility and aesthetics. In comparison to conventional concrete, its compressive strength is 6 to 8 times superior and its flexural strength is 10 times superior. Ductal® provides architects and designers with an exceptional freedom to meet any design requirements, offering structural and architectural functions.

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ROOF

POSSIBLE DESIGN APPLICATIONS UHPC Ductal® provides an innovative solution for roof structures. Ductal® roofs can be designed for specific projects with high demands for structure and aesthetic integrity. Below are three different projects demonstrating three different design applications: a one-way precast slabs for long spans with irregular openings, a thin shell canopy structure and cantilevered structure

©Ashford Brown –Jean-Michel Labat & Philippe Caron

1 ONE WAY PRECAST SLAB Ductal® is ideal for the use in one-way spanning systems which demand a possibility of a lightweight structure and skylight openings. Done with a conventional system, this would be too heavy for the building’s structure and would result in a much thicker overall appearance, due to structural demand and the requirements of steel reinforcement.

One way precast Ductal® slab

2 THIN-SHELLED CANOPY STRUCTURE Ductal® can be precast into almost any complex and intricate three dimensional form. Because no set up or space is required for reinforcing bars, physics of the resulting geometry places the only limit on the forms possible. This type of system is best taken advantage of for open outdoor spaces, as no additional roofing materials such as insulation are then required. Thin-shelled canopy structure with Ductal®

3 CANTILEVER ROOFS

©Leon Grosse, Rudy Ricciotti

Ductal® has superior flexural resistance while maintaining a thin profile. This makes it a great choice for cantilever roof structures. The example to the left has a cantilever of 7.8m for instance.

Cantilever structure with Ductal®

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LIGHT AESTHETIC UHPC ROOF

4. System performances + CUSTOM FORMS

+ PERFORATED

COMPLEX

STRUCTURES

UHPC Ductal® is reinforced with metallic fibers. therefore it allows possibilities of regular and irregular openings in the roof structures. This is due to the absence of the steel reinforcement. Perforation in the roof can contribute to: • Light filtration • Open air circulation • Energy enhancement Glazing can be incorporated in The use of Ductal® for the roof perforations. There are lightweight aesthetic roofs two types of integration: allows for an increase in spans, • Glass being installed above a reduction in the number of the openings sections to the overall design • Glassing incorporated into and eliminates the otherwise the openings during pouring required reinforcement to create of roof elements. structures that are not possible in comparison with some These possibilities gives materials. architects the ability to play with light and allow maximum natural light into the space while maintaining structural integrity of the roof

SURFACES Superior architectural surface: Ductal® offers versatility with endless variety of different textures and colours that appeal to current architectural trends and applications: purity of line, elegant forms and delicacy and mineral bias. The combination of colours, textures and forms Ductal® provides creativity and therefore is able to adapt and fit almost any design specification for roofs structures with high demands. Variety of colours: Treated by incorporating pigments directly into the mixture Ductal® produced in the lightest shade to the darkest. Different textures: Possibility of intricate textures with durable smooth finishes.

©Leon Grosse, Rudy Ricciotti

©Leon Grosse, Rudy Ricciotti

©Lafarge

Ductal® has extremely high mechanical performances such as compressive resistance, flexural strength and ductility. By utilizing this unique combination of properties, architects and designers can create thinner and therefore lighter elements that are more graceful with the possibility of innovative geometries.

+ ARCHITECTURAL

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ROOF

+ DURABILITY

+ LIGHTWEIGHT

+ SIMPLE IMPLEMENTATION

Ductal® is reinforced with steel fibers and thus simplifies construction through the elimination of reinforcing steel. Ductal® has the ability to create thin lightweight structures that would otherwise be impossible with conventional concrete. Ductal® has a strength similar to metals. This strength and absence of steel reinforcements makes the creation of thin and thus lightweight roof structures possible. In addition, a roof with a thin profile provides low impact on the space and supporting structure giving the overall structure the possibilities to maintain a thin and light profile. The ability to provide high strength, thin elements is also helpful when designing for historic preservation or other restoration projects.

Ductal® lightweight roof elements are precast, allowing for tight quality control and timely on site installation Ductal® thin roofs are efficient structures, using less material to construct an extremely durable and customizable structure. The precast system and lack of steel reinforcements, and thus onsite formwork, reinforcement design and installation, aids in simplifying the design and construction process for Ductal® lightweight roofs. In addition to the natural durability of Ductal®. Each project’s customised geometry is put through rigorous structural tests making it a more durable system, requiring less maintenance over time.

©Ashford Brown –Jean-Michel Labat & Philippe Caron

©Leon Grosse, Rudy Ricciotti

Ductal® is suitable for roofing due to it’s impermeability to water and other characteristics which contribute to its extreme durability. Reinforced with fibers with a precise matrix design, Ductal® is significantly stronger than conventional concrete (with strengths similar to some metals) and performs better in terms of abrasion and chemical resistance, freezethaw, carbonation and chloride ion penetration. The closed microstructure of Ductal® allows it to be highly resistant to environmental pollutants and other factors which would otherwise damage ordinary concrete. Ductal® has an aspect of the sealing material from a certain thickness of 2530mm which overcomes other sealing solutions proven in the Villa Navarra, Jean Bouin and Shawnessy projects.

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LIGHT AESTHETIC UHPC ROOF

5. On-site implementation Formwork positioned for casting Ductal®

1 FORMWORK DESIGN Ductal® formwork must be carefully designed and built. Geometric dimensions and tolerances must be highly accurate in accordance structural design tolerances. Once these designs are finalized precast formwork is constructed with the pouring direction kept in mind as a priority for construction. The fibers of Ductal® flow in the direction of the pour and, for optimal structural performance, need to be going in a perpendicular direction to the forces being acted on the element.

Disassembly of the mold

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CASTING

The piece is cast, keeping in mind the surface quality. (need more information on time required)

Mechanised demolding of Ductal® element

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DEMOLDING

©Lafarge

Due to the large span and complex shapes possible with Ductal® lightweight roofs structural supports are needed to assist with the demolding of the roof elements.

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ROOF Assembly and transportation of the Ductal roof

4 ASSEMBLY (DESIGN SPECIFIC) These elements are then assembled depending on the needs for the design. This step is an option completely dependant on the design of the roof. (find details of sealants if applicable and if at this stage)

5 TRANSPORTATION The completed elements are secured to a loading truck and brought to the site.

Installation of the Ductal roof ©Lafarge

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INSTALLATION

The Ductal® elements are then installed using steel connectors and a crane lift.

Maintenance A heat treatment cycle can be applied to the Ductal® material after setting. This treatment consists of subjecting the structures to a temperature of between 60 and 90°C for a period of 48-72 hours. This specific feature of the Ductal® process accelerates maturation of the material and gives it dimensional stability immediately after manufacturing, thereby increasing its durability in harsh environments. NOTE: The premix must be kept dry at temperatures over 10°C and should be consumed within three months of delivery. Ductal® concrete is produced according to a strictly defined procedure which requires precise weight portions

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ROOF

6. Environmental performances Lightweight Aesthetic Ductal ® Roofs and the main labels/certifications Lightweight Aesthetic UHPC roofs produced with Ductal® can contribute to the main environmental labels. A first assessment of the credits or targets met by this system is given below. They are project dependant and must be adapted accordingly.

LEED

BREEAM Man 03: Construction Site Impacts Ductal® Roofs encourage construction sites managed in an environmentally sound manner in terms of resource use, energy consumption and pollution due to being precast: always custom designed with installation in mind.

HQE HQE - Target 2 (up to 7 Points) 2.3.1: Determine the Environmental Impact of the Construction Products HQE - Target 2 (up to 3 Points) 2.3.2. Choose Construction Products to Limit the Environmental Impact of the Building

Man 12: Life Cycle Cost Analysis Ductal® Roofs are advanced designs using specific, extremely durable material which encourage the development of a Life Cycle Cost (LCC) analysis model for the project to improve design, specification and through-life maintenance and operation.

Credit / Target

Credit 7.2 Heat Island Effect –Roof Ductal® Roofs can contribute to Heat Island Effect in cities, project dependant providing the element is designed in a vibrant white color. This is because the white color does not absorb the heat under certain conditions by reflecting part of the sun energy. Up to one point can be awarded with this category, this credit must be adapted accordingly, MR Credit 1.1: Building Reuse – Maintain Existing Walls, Floors, Roof The intent of this credit is to extend the lifecycle of a buildings to conserve resources and reduce the waste and environmental impacts generated from new building construction. Ductal® Roofs can be used for renovation to improve structural stability while maintaining the existing building structure and envelope as they provide lightweight and customized structures. Up to three points are possible in this category.

IEQ Credit 8.1 Daylight and Views—Daylight  Ductal® Roofs with perforations allow natural daylight to penetrate deep into the regularly occupied areas of the building. The perforations in the roof can enhance daylight uniformity inside the building by creating unique opportunities for daylight use in interior spaces within the building.

Mat 01: Materials Specification Ductal® is durable concrete with a low environmental impact, over the full life cycle of the building.

HQE - Target 2 2.3.3: Choose Construction Products to Limit the Environmental Impact of the Building Up to 2 credits can be obtained if it is demonstrated that the transport strategy for the materials and products limits the impacts in terms of CO2 emissions. Specific calculations need to be done, due to Ductal roofs being precast is performant on this criterion (local material produced in operations)

Wst 1 Construction Site Waste Management  Roofs made out of Ductal® generate very little waste on the construction site as they are precast and ready to install when they arrive on site.

HQE - Target 3 3.1.2. Reduce Worksite Waste at the Source Integrated choice of products, systems and construction processes.

Hea 1 Daylighting  Ductal® Roofs with perforations allow natural daylight to penetrate deep into the building. They can enhance daylight uniformity inside the building by creating unique opportunities for daylight use in interior spaces within the building.

HQE - Target 10 10.1.4 Quality of Natural Light Treatment 2.-4 Points. Ductal® Roofs with perforation provide penetration of natural light into the building with the openings exposed to the sun. This filters and diffuses daylight in these spaces in order to control the incoming natural light inside the building, further reducing problems associated with glare in occupied areas within the building.

Innovation in Design Credits Depending on your project location, project type and building design, this system could contribute to an Innovation in Design Credit.

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ROOF

8. Contributions to buildings and cities All Lafarge’s Efficient Building Systems have been peer-challenged by a panel of external and experienced architects and engineers to meet and anticipate their expectations. This panel considers that a sustainable building must be affordable, autonomous, connected, easy-to-build, efficient, long-lasting, respectful of identity, responsive, robust and transparent. A resilient city is characterized by its adaptability, biodiversity, continuity, decentralization, diversity, preparation and redundancy (see the related introductory document). The name given to the system enhances the above properties. The most pertinent characteristics are described below.

A building should inspire confidence; people should be able to understand, monitor and modify the way it functions. . A building’s efficiency should remain normal circumstances.

constant over time in

A building should be able to resist extreme

circumstances.

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A building should be constructed quickly without much qualified labor.

A city should be able to adapt to changes in the environment.

A city should successfully incorporate its rich past new environments.

heritage and

A city should comprise an important diversity of buildings making it

dynamic for a variety of populations. 14

This system is easy to understand. It inspires confidence with unrivalled aesthetics and technical identities. its function and impact on the building is apparent to the users. The exceptional durability of Ductal® makes this system very long lasting and requires a very low maintenance

Due to its very low porosity, Ductal® offers exceptional durability and resistance to external effects such as abrasion, impact and chloride environment therefore it is robust This system is easy to build as it is precast and therefore easy to implement. It does not require qualified labor.

This system does not have an impact on the interior design of the building therefore it supports the flexible design of individual living environments. The possibilities of building lightweight roof elements with Ductal contribute to replacement of roofs for renovation, so no reinforcement is required for the existing structure. The properties of Ductal® offer freedom to creativity and possibilities of unique forms, a great variety of colours and patterns proposing diversity to the city making it dynamic.

LIGHT AESTHETIC UHPC ROOF

9. Related information OTHER SYSTEMS FOR AESTHETIC CONCRETE SURFACES

PERVIOUS CONCRETE SURFACES – HYDROMEDIA 8.2.2

CONCRETE LAWN LATTICE SURFACES 8.2.3

INSULATED SEMIPRECAST DOUBLE WALLS 2.1.2

UHPC SUNSHADES 2.6.2

DOUBLE SKIN CONCRET WALLS 2.1.14

MATRIXED CONCRETE FACADES 2.5.3

LAFARGE PRODUCTS

DUCTAL®

USEFUL LINKS  http://www.ductal-lafarge.com/

The following information represents only suggested procedures, and since they have not been developed by Lafarge, Lafarge accepts no liability for the consequences of any actions taken on the basis of the information provided. The content of this catalogue is for information purposes only, and may not apply to your situation. Lafarge provides no warranty about the content or accuracy of content enclosed. Information provided is subjective. Keep this in mind when reviewing this guide. Lafarge is not liable for any loss of profit or any other commercial damages resulting from use of this guide. If you are not the intended recipient you are notified that disclosing, copying, distributing or taking any action in reliance on the contents of this information is strictly prohibited.

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©Ashford Brown, Jean-Michel Labat & Philippe Caron

©Leon Grosse, Rudy Ricciotti Credits:

LAFARGE Calle Orense 70 28020 Madrid España [email protected] + 34 91 376 98 00 www.lafarge.com.es

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