Rigid PUR (Polyurethane) and PIR (Polyisocyanurate) insulated panels are extremely strong, long-lasting, and thermally resistant insulation that suit the needs of a wide range of construction and building applications, if you are about to buy PUR or PIR insulated sandwich panels for your modern building, this comprehensive guide determine the differences between PUR and PIR based on various factors such as insulation performance, thermal resistance, composition, benefits, and cost, which help architects, builders, and contractors choose the best material that meet their requirements, while gaining a proper understanding about different types of PUR and PIR insulated panels.
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To make the best choice between PUR (Polyurethane) and PIR (Polyisocyanurate) insulated panels, it is very important to determine the differences between their composition, insulation value, and compressive strength:
Polyurethane (PUR/PU) and Polyisocyanurate (PIR) are derived from polyurethane, and both are made from a reaction of polyol liquid and polymeric isocyanate or a mixture of MDI (Methylene Diphenyl Di-isocyanate), however, to create PIR, blowing agent is added to a mix of polyols, isocyanates, and other additives. The manufacturing process of Polyurethane (PUR) and Polyisocyanurate (PIR) results in rigid closed-cell structure foam which ensures thermal insulation, dimensional stability, fire resistance, and enhanced moisture resistance, thanks to their thermally resistant properties, chemical, and physical composition which makes them the best choice for a wide range of building applications including interior and exterior walls, partitions, roofs, floors, facades, and building envelopes. Below you will find more information about the composition of Polyurethane (PUR) and Polyisocyanurate (PIR):
Polyurethane (PUR, PU, or urethane) is a highly cross-linked polymer that forms a rigid molecular structure and refers to a class of polymers that contains two types of monomers, it is produced by reacting a polymeric isocyanate, mostly aromatic diisocyanates, toluene diisocyanate (TDI) and Methylene diphenyl diisocyanate (MDI) with polyols, catalyst/tertiary amines, and organic chemicals such as DABCO (known as triethylenediamine or TEDA), DMDEE, or metallic soaps like dibutyltin dilaurate that are bonded by urethane linkages. The reaction between these properties results in a heat-curing thermosetting material that does not melt on heating.
Polyisocyanurate (PIR, Polyiso, or ISO), is a Thermosetting Polymer (or a Thermoset plastic) which contains similar starting material used in polyurethane (PUR) including isocyanate that reacts with polyether after catalyst action, except that the proportion of Methylene Diphenyl Diisocyanate (MDI) is higher than PUR, while polyester-derived polyol is used in the reaction instead of polyether polyol, and the catalysts and additives are also different from those used in the production of PUR, this result in a chemical structure with complex polymeric structure. However, when compared to (PUR), the PIR (Polyisocyanurate) foam contains a high degree of aromaticity which forms the polyisocyanurate structure, provides higher thermal stability, and improves fire resistance; this makes them ideal for residential building insulation, industrial facilities, cold storage, chemical plants and oil refineries construction.
Generally, the R-value measures the thermal resistance of insulation material and its ability to resist the heat flow, however, higher R-values offer better insulation performance and greater insulating properties which increase thermal resistance, improve energy efficiency, and hence reduce heating and cooling costs. Polyurethane (PUR) R-value is typically R 5-7.1 per inch, while Polyisocyanurate (PIR) R-value ranges between R 7 and 7.2 per inch. However, when compared to PUR, PIR has a higher insulation R-value and low thermal conductivity, therefore, PIR insulation is one of the most thermally efficient insulation materials which provides superior insulation performance while it reduces effectively heat loss more than other insulations with similar thickness, this insulation qualities makes the PIR sandwich panels the first choice for builders and homeowners.
PUR and PIR structural panels have become the best choice for lightweight construction and building applications that require compressive strength of 150-400 kPa, polyurethane foam (PUR) is essentially made of closed-cell structure and hard polyurethane foam, thanks to the rigid insulation, which allows PUR to resist compressive strength and ensure a high mechanical performances for various building envelopes including industrial zones, warehouses, showrooms, garages, workshops, cold rooms and agricultural halls, besides this, PUR insulation can withstand exceptional mechanical loads while it can ensure excellent dimensional stability. Also, PIR sandwich panels are made from a tough, durable, and low-weight PIR insulation core which is nestled between two sheets of galvanized steel sheet, pre-coated galvanized steel (PPGI/PPGL), aluminum alloy skin layers, stainless steel facings, FRP/fiberglass sheets, plywood boards, etc.
PUR and PIR sandwich panels offer an excellent thermal conductivity/lambda (λ) value which ranges for PUR from 0.025 to 0.035 W/mK and PIR between 0.022 and 0.027 W/mK, also, RPURFs (Rigid Polyurethane Foams) provides an R-value of 7.0 – 8.0 per inch of thickness, while PIR (Polyisocyanurate) foams an R-Value of 6.0 per inch of thickness, due to the low conductivity blowing gases trapped in their closed porous structures and their physical and mechanical properties, PUR/PIR insulated sandwich panels deliver proven thermal performance that meets the most demanding insulation requirements for contemporary architecture and modern construction. Also, when compared with other conventional insulating materials, PUR/PIR insulation can dramatically reduce the load on heating and cooling systems which helps maintain consistent temperatures in winter and summer, improve the energy efficiency of buildings while minimizing the emissions of CO2 and protecting the environment.
Polyisocyanurate (PIR) offers better fire performance when compared to Polyurethane (PUR), thanks to the non-combustible material and fire retardant properties which offer high resistance to flames while it generates less smoke when exposed to fire. However, PIR is preferred for building insulation applications where fire safety is an essential requirement, unlike PUR foam which has limited fire resistibility and emits less smoke during real fire events, PIR foam does not melt or drip when exposed to fire, this slows the spread of flames and reduces the smoke emitted from the fire when compared to PUR panels. PIR sandwich panels are FM Approved to FM for fire performance (rated as Class 1 roof) and pass FM fire tests for Class 1 Insulated Steel Deck, and ANSI UL roof deck construction, whereas, PU sandwich panel is rated according to the fire classification of building materials B1, B2 and B3:
Class B: Combustible materials
Class B1: Flame Retardant
Class B2: Normal Flammability
Class B3: Easily Flammable
Rigid polyurethane foam (PUR) is a waterproof building material that does not allow water to flow through the building envelope, nor absorb water, vapour, or humidity, given its closed cell structure, low vapor permeability, and low capillary absorption rate, polyurethane offers high resistance to external factors such as adverse weather conditions such as heavy rain, wind, snow, frost, hail, hurricanes, extreme temperature, and climatic changes. Likewise, PUR sandwich panels are watertight structural components; each unit is bonded to strong metal sheets and coated with anti-corrosive finish paint. Similarly, Polyisocyanurate (PIR) is inherently water resistant; thanks to the hydrophobic nature of the polyiso core and aluminium-faced panel which provide superior water resistance compared to other rigid foam insulation. PUR and PIR sandwich panels are demonstrated to be water-resistant, this makes PUR and PIR ideal for various applications including masonry cavity walls, exterior walls, building envelopes, foundations, floors, and roofs.
Generally, Polyisocyanurate (PIR) foam is highly resistant to moisture and water penetration than Polyurethane (PUR), also, PIR sandwich panels are made of high-strength steel sheets, which are sealed to prevent water from infiltrating the PIR foam core and moisture intrusion, this makes PIR more resilient and preferred for wet and humid environments, as well as areas where buildings are exposed to moisture and humidity, also, given their closed-cell foam, inert and non-biological resistant properties, PUR and PIR insulation can withstand microorganisms and biological aggression, water leaks and vapor, and hence can provide high thermal performance and ensure structural integrity to building envelopes such as interior and exterior walls, walls partitions, roofs, facades, and structures.
Closed-cell rigid polyurethane (PUR) and polyisocyanurate (PIR) are designed and manufactured to form a strong barrier within a building’s interior and exterior environment against the impacts of acoustic atmospheres, thanks to the sound-absorbing insulation material which ensures excellent sound-absorption of sound waves, airborne sounds and noise pollution in modern residential, commercial, and industrial buildings, this makes PUR and PIR sandwich panels ideal for soundproofing walls, roofs, ceilings, floors, building disclosures, building envelopes, doors and windows. Also, despite the lightweight PUR and PIR insulation cores, acoustic sandwich panels and sound absorbing panels can effectively reduce the noise level of machinery in production plants, while ensuring maximum comfort, and wellness for building applications that require a high level of acoustics comfort such as marine ship, cruise ship, naval vessel, yacht, fishing boat, aerospace, and automotive applications.
Polyisocyanurate sandwich panels (PIR) can last for 20 years under normal wear and tear, due to the inert insulating material and closed-cell PIR properties, PIR insulated panels can resist rot, and decay and deliver high-performance insulation values throughout the lifetime of the building. Whereas, polyurethane rigid foam (PUR) has an average lifetime of 50 years or more, given its cellular structure closed-cell structure and rigid insulation foam, PUR composite panels can maintain their thermal resistance for a long period while they withstand aggressive climates and impacts of environmental factors such as moisture ingress, fungi, bacteria, molds, humidity, or air movement or other microorganisms.
PUR and PIR sandwich panels are highly versatile in applications, and come in endless appearances, finishes and colors that suit the functional and aesthetics requirements of homeowners and construction professionals, some of the common features of PUR/PIR insulated sandwich panels include:
Orientation: horizontal and vertical orientation
Profile Options: embossed, non-embossed, micro-rib, mini micro-rib, mini-wave, Shadowline, etc
Polyurethane (PUR) is generally less expensive than Polyisocyanurate (PIR), this is due to the high cost of the PIR production process which is more complex and involves additional raw material, processes, and chemicals, this impacts the price of the final PUR and PIR sandwich panel. However, despite the high price of Polyisocyanurate (PIR) insulated panels, they offer a great thermal value which reduces energy consumption and decreases the cost of cooling and heating for the long term.
PUR/PIR sandwich panels have become the top choice for low-energy buildings and sustainable architecture which require superior insulation performance for low-rise structures and high-rise buildings, and at the same time it ensure energy efficiency, cut CO2 emissions, and significantly reduce greenhouse gas emissions. Besides, Polyurethane (PUR) and Polyisocyanurate (PIR) sandwich panels are recyclable and reusable, the recycling involves melting the metal skin-layers while PUR/PIR are recycled using several methods such as mechanical recycling, and chemical recycling by glycolysis or incineration with energy recovery, this reduces waste and ends up landfills and makes the environment more sustainable.
Nowadays, PUR (Polyurethane) and PIR (Polyisocyanurate) insulation are both preferred for different types of building and construction applications including timber/metal framed buildings or masonry applications, whether you are an architect, contractor, or real estate developers, you can choose from a large selection of PUR/PIR sandwich panels that includes the following:
PUR/PIR wall insulation, cavity insulation, external and internal cavity walls, timber or steel frame walls, foil faced, plasterboard or cement particle board.
PUR/PIR insulated metal panels (IMPs) or PUR/PIR insulation board with core sandwiched between two metal facings (Galvanized steel sheets, Aluminum or Stainless steel facings).
PUR/PIR insulation bonded to plasterboard or cement particle board for solid masonry walls or timber frame lining applications.
PUR/PIR Roof insulation, pitched/flat roofs, warm roofs, insulated roof decking (Plywood or chipboard roof boards).
PUR/PIR Architectural facades insulation and floor insulation.
PUR/PIR Cold storage insulation, cold room panels, refrigeration panels, freezer panels, and duct panels.
PUR/ PIR insulation bonded to plywood, OSB board, or coated with mineral glass
PUR/PIR sandwich panels are available in various sizes, thicknesses, strengths, and facings material.
PUR/PIR insulation comes in standard and custom-made boards and can also be engineered and customized for specific applications.
In conclusion, making the best choice starts with understanding the difference between PUR and PIR, this depends mainly on a wide range of factors including thermal conductivity, strength-to-weight ratio, soundproofing, applications, materials, features, and cost, this allows architects, builders, and contractors to construct modern steel buildings and structures that help to build owners achieve high insulation performance, energy efficiency, and comfort, while it meets the highest industry standards and responds to the exact requirements of local building regulations in your region.
Paint
Pre-painted metal is obtained by painting galvanized steel and aluminum in a continuous production line, with coil coating technique. In coil coating technique, galvanized or aluminum roll is opened in the continuous painting line and firstly, surface cleaning process is applied. The oil and unwanted substances are removed from the surface to be painted. Then, chromating process is applied to the sheet's surface and a surface suitable for painting is obtained. Firstly, epoxy primer is applied on both sides of the metal and it the primed metal is then sent to an oven for curing. The insulating layer or its adhesive is adhered to the metal by means of the epoxy primer layer applied to the insulated surface of the metal. And by this way the sandwich panel gets a composite structure. Since there is no epoxy primer layer in the insulated layer of the naked embossed aluminium, insulation layer cannot adhere to the metal very well and it can shear off in time.
Color
The colors desired as a final coat are selected from the RAL catalogue. It is painted in RAL color and type, and cured again. Rolls wrapped as painted. With Coil Coating technique, a uniform paint thickness is obtained at every point of the steel surface. Due to the geographical and environmental characteristics of the projects's location, polyester, PVdF, plastisol, foodsafe or polyurethane paint is used on the epoxy primer. These paints with different technical characteristics common point is to be wet paints. Paint is the most important factor that ensures metal's long lasting. The metals painted with coil coating technique can be processed easily.
Painted surface is not affected during the forming process. Paint types have different warranty periods. These periods vary depending on the environmental, geographic and climatic conditions and use. The endurance of coil coating painted sheets is 6 years for the polyester paints under normal conditions and for PVdf and plastisol paints at locations without air pollution, acidic and heavy metals and away from the sea and for about 15-20 years. In case of continuous maintenance, the expected life can be 20 years and over.
Tone differences may occur when the colors in the RAL catalogue are applied onto the metal. Therefore, in project productions, production should be made by using the rolls painted in the same batch. A protective film is applied to the outer surfaces of the painted sheet metal. The film layer must be stripped off the paint surface before screwing during installation.
Polyester
Polyester is the most simple and widely used topcoat paint among the paint types. It is widely used in interior and exterior surfaces. It is economical and it can be shaped easily. Since it has most appropriate cost, it can be supplied in all RAL codes.
PVdf
PVdf is a topcoat paint which is the most resistant against UV rays, moisture and humid environments and heat. It is especially used in exterior metal surfaces in buildings close to coasts and seaside. Since it has excellent UV resistance, it is the most resistant paint against color fading.
Plastisol
Contact us to discuss your requirements of PUR/PIR Roof Panel. Our experienced sales team can help you identify the options that best suit your needs.
Plastisol is the topcoat paint that is resistant to acidic and alkaline environments. Its resistance to corrosion and chemical oils is at the highest level. It is a flexible and thus shaped easily. It has high impact resistance. Plastisol can not be used in exterior surfaces in hot countries since its UV resistance is low. It shows superior performance in cold, humid climates. If desired patterns can be formed on the surface.
Silicone Polyester
Silicone modified polyester is a topcoat paint with high solvent resistance. It has high corrosion and temperature resistance. It is an impact resistant paint that it is easy to clean. Silicone is suitable for application in high-rise buildings due to its color brilliance and resistance against fading.
Performance Table of Paint Types
Comparative Properties and Performance Table was created to provide a description of various roll coating topcoat paint physical and performance characteristics. This chart is intended to provide general information only. Since Performance Table addresses only for the topcoat, the graphics can only describe the overall system performance.
Division of Colours in Terms of Degree of Heat Absorption
Sandwich panels consist of three layers such as external sheet, insulation core and internal sheet. Due to physical properties of these layers, Sandwich panels are open to the harmful effects caused by different indoor and outdoor temperatures in terms of thermal expansion and rigidity. Steel, forms the outer and ınner surface of panel, has a higher expansion and shrinkage values than insulation core under the temperature. And because the steel is joined with the back coat to the core insulation and has different expansion properties, layers can be seperated, ondulation can be seen as bubbles and bulges when the limit values exceed under high temperature.
Light coloured panels stresses do not reach limit values while the dark and very dark colours influence must be taken into account and added up to the calculation of permanent and variable loads (panel dead load, structural loading, wind and snow load, etc.) Another harmful effect results from the fact that sandwich panels always operate between two environments with different temperatures. Normally, indoor temperature is above zero (+20°C) while the outside temperature is sub-zero (-30°C). Quite opposite conditions may occur in the case of freezers where indoor temperature may reach even -40°C while outdoors +30°C. As a result, external and internal surfaces behave differently - cold surface shrinks while warm lining expands, which causes bending of the entire panel.
In order to assess the influence of thermal loads on the panels, all available colours have been divided into three brightness groups, based on the degree of heat absorption. According to the EN : standard, the temperature of external lining (T1) reaches maximum value in summer, and depends on the colour and the degree of reflection of the surface. The T1 values that are minimum values for load capacity calculations and sufficient for calculating limit conditions of use are as follows:
Very light colours, Light colours, Dark colours, Where RG is the reflection grade in relation to magnesium oxide (100%)
As you can see from the values dark coloured panels expose to thermal load compared to light coloured panels. Due to light coloured panels, dark coloured panels have higher risk of fading, abrasion, colour gradation and ondulation risk.
Polyurethane (PUR)
Polyurethane is rigid polyurethane foam formed by the mixture of two main components named as polyol and isocyanurate under special production conditions, with catalyst materials and under high pressure. It has a closed cell structure. Thereby, it can provide excellent thermal insulation. Polyurethane density must be between the range of 40 (± 2) kg/m3 so that the thermal insulation coefficient is at the desired value and for the carrier characteristics of the panel. It has high dimensional stability. Water absorption is not available, it floats on water. No bacteria grows inside. Its usage performance is good since it has high compressive strength. Usage temperature should be 70-80°C maximum. Maximum resistance temperature is 100-110°C. Above this temperature it loses its characteristics.
Polyisocyanurate (PIR)
Polyisocyanurate (PIR) is formed as a result of the chemical reaction between the PMDI (polymeric methyl diphenyl isocyanate) or MDI and polyol. The amount of the mixture of MDI and polyol components differs polyisocyanurate from polyurethane. The amount of MDI used in PIR production and the amount of the flame retardant catalyst are higher. PIR is composed of isocyanurates chains which have higher chemical stability at high temperatures. PIR's flammability and smoke generation is very low compared to polyurethane. It creates excellent thermal insulation due to its closed cell structure. PIR should be used at maximum 80-90°C. Its maximum resistance temperature is 100-110°C. After this temperatures, it loses its function.
Rockwool
Rockwool is formed by melting the inorganic raw materials (basalt) at °C-°C into fiber. No change occurs in size even if it is exposed to moisture and humidity. It does not deteriorate, become mouldy, corrode or rust. Rockwool can not be destroyed by insects and micro-organisms. Rockwool plates are sliced in our fully automated production facility so as to fill in the ribbeds and made perpendicular to the panel surface and thus compression strength of the sandwich panel is increased. Rockwool provides high fire safety as well as heat, noise insulation and acoustic layout.
Acoustic Panel
This insulating sandwich panel has been designed to offer a better sound absorption. Made of a mineral wool core and two prepainted steel facings, its outer facing is plain and its inner facing perforated.
Expanded Polystyrene (EPS)
Expanded Polystyrene (EPS) is a petroleum derivative thermoplastic material. It's very small polystyrene beads expand when heated with water vapor. They start to swell up due to the pentane gas and then adhere to each other firmly, and they take the form of the mold they are contained. Pentane gas is replaced by air at the end of this process. This still and dry air trapped in small closed porous particles enables EPS plates have superior thermal insulation properties. The moisture level of the blocks to be used in sandwich panels is reduced below 2% by drying in special furnaces. Then, they are cut in desired thickness. It is the most economical and lightest product among the thermal insulation fillings.
Kraft Paper
Kraft paper is produced from softwood trees resistant to high moisture, such as pine, fir, spruce with longer fiber by processing with sulfate or alkaline. Kraft means strong in German. Kraft papers are usually produced in dark, ie. natural color. They have high tensile strength and elasticity. Their strength indicator explosion values vary between 3.5-5 kPa and their weight vary between 110-140 g/m2.
PVC/TPO Membrane
In low slope roof systems with a slope under 5%, one side membraned roof panels are used. PVC (polyvinylchloride) and TPO (polyolefin) membranes are insulation membranes that are laminated with reinforced felt layer and welded together with hot air ,resistant to atmospheric conditions and UV. Thanks to the polyester reinforcement, it has a high resistance to tearing and dimensional stability. Reinforced laminated felt layer ensure strong adhesion of membrane to the insulation core and prevent direct contact of membrane with insulation core. It provides fire, heat and water insulation in low sloped roofs.
GRP (Glass Reinforced Fiber)
GRP plates are composed of Glass Fiber Reinforcement and polyester resin. They differ from many other materials due to their properties. GRP (Glass Reinforced Polyester) coating and insulation is a form of superior coating obtained by providing a chemical reaction with the addition of glass fiber mat and a carrier matrix resin (polyester) with high mechanical properties. In addition of the thermal insulation Roof Panels with GRP supplied, also resistant to chemicals and high temperature because of its corrosive properties. GRP material's shape does not change since it is a thermosetting plastic. And, it provides heat resistance between -40°C to + 120°C. It is resistant against impacts and vulnerable to breakage. GRP sheets when used as a substitute for the lower sheet of the roof panels; provide solution to problems such as thermal insulation, hygiene and corrosion, which are frequently encountered in the industrial buildings, chemical production facilities, food plants, manure drying facilities, sports facilities, thermal swimming pools and constructions in the agriculture-livestock sector.
Painted Galvanized Sheet
Painted galvanized steel sheets are hot dip galvanized by continuous process in accordance with EN : standards, with 100-275 gr/m2 zinc-coated. Galvanized coating improves corrosion resistance of the sheet. Due to its hardness, galvanized sheet is resistant to impacts and abrasion. On load bearing layers, galvanized sheet thickness should be minimum 0,50mm.
Aluminium
In sandwich panels, aluminium with a flat or embossed surface is used. It can be used as natural, preservative lacquered or painted. Aluminum's corrosion resistance is a very high. It is light weighted and it is a good conductor. It is preferred in acidic or corrosive environments or under heavy industrial conditions. Since its expansion coefficient is quite higher than the galvanized sheet, its adhesion to the insulating material is weaker. It is not recommended in climatic conditions with night and day high temperature differences.
In sandwich panels, load bearing layer thickness should not be thinner than 0.50 mm and in corrugated sheets, the sheet should not be thinner than 0.70 mm.
Stainless Steel
Stainless steel is especially preferred in the interior and exterior surfaces of the Cold Storage panel for hygiene because of its acidic environmental durability and corrosion resistance. It is produced in different qualities. Products should be selected by taking only the mechanical and chemical values into consideration. 316,304 and 430 grade stainless steel values in the following table are stated since they are the most frequently requested products on the market.
PVC Laminated Steel
Galvanized and aluminium layer laminated PVC film can be used in indoor or outdoor environments.
With its flat surface, textured and wood patterned alternatives, it offers a wide range of application possibilities. PVC films provide practical and effective usage scope in different sectors with its food safety, non-toxic, non-flamable, UV resistant, hygienic, ease of cleaning and suitable for the mechanical environment
Aluzinc
Aluzinc, Zincalume or Galvalume are different names of the same product, which is recently being used in interior and exterior surfaces of the sandwich panel. It consists of 55% Aluminum, 43.4% Zinc and 1.6% Silicone.
Aluzinc is 2-6 times more corrosion resistant than the galvanized sheet due its aluminum and zinc content. Aluminum forms a layer between the steel surface and the atmosphere to obtain protection. This aluminum barrier, i.e. its extremely resistant aluminum oxide coating, does not dissolve in most environments and provides a long-lasting protection against corrosion. However, zinc provides a similar protection with the hot-dip galvanized sheet (e.g. against situations such as when steel comes out in surface layer as a result of possible cuts and scratches). In principle, zinc reacts instead of steel plates as it is referred to as sacrificial cathodic protection. By protective synergy of aluminum and zinc, Aluzinc provides a strength far beyond the protection provided by the aluminum or zinc alone.
Due to its atmospheric corrosion resistant structure, it provides assurance against rots and perforations. It is capable of reflecting solar radiation.
PET (Polyethylene Terephthalate)
Polyethylene terephthalate (PET, PETE, PETP) is a thermoplastic material of the polyester range produced by the poly condensation method. Its softening temperature is approximately between 70 °C - 80 °C. It is not deformed up to this point and it is resistant to breakage. It can reach above 140 °C when it is in the crystal form.
Its melting point is between 235 °C and 260 °C (depending on the degree of crystallization and degree of polymerization). It serves as a barrier against gas and moisture. PET forms the bottom layer of the sandwich roof panels which are used in acidic environments, Food Plants, Chemical Manufacturing Plants, Fertilizer Drying Facilities, Sports Facilities, Thermal Swimming Pools and constructions used in the Agriculture-Livestock Sector.
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