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Proof-Load Testing Lifting and Handling Fixtures: The 125% Rule

A proof-load test hangs a known load above the rating on a lifting or handling fixture before the fixture carries production loads, and 125 percent is the figure the federal construction rule and the Navy's weight handling program use for it. UTEC Industrial designs, engineers, machines, fabricates, and installs custom material handling systems for aerospace and heavy industry from its Spokane Valley, WA facility, integrating Allen-Bradley PLC and motion control with in-house CNC machining, heat treating, and stress relief. This article sets out which rule states 125 percent and for whom, what the test proves and what it leaves open, and how the load is chosen, weighed, held, repeated, and recorded. The test sits in the middle of the build chain, design → engineering → parts machining → fabrication → assembly → weld fatigue → stress relief → drives → controls → tuning → monitoring: it checks the fabrication and assembly steps before it, and it sets the baseline that commissioning and monitoring work from.

Where does the 125 percent figure come from?​

Several of the documents cited here put "125 percent" next to a lifting test, and they do not mean the same thing:

  • Construction law. 29 CFR 1926.251(a)(4) requires special custom design grabs, hooks, clamps, or other lifting accessories, for such units as modular panels, prefabricated structures and similar materials, to be marked to indicate the safe working loads and proof-tested prior to use to 125 percent of their rated load. Part 1926 is OSHA's construction standard.
  • Navy. NAVFAC P-307's Table 14-1 sets a 125 percent test load for below-the-hook lifting devices (except as noted), beam clamps, equalizer beams and flounder plates, lifting beams, portable padeyes and lugs, plate clamps and other pressure-gripping clamps, and vacuum lifters. It sets 200 percent for electromagnetic lifters and 300 percent for permanent magnetic lifters.
  • DOE. DOE-STD-1090-2020 sets the test load for miscellaneous lifting devices, which may include custom lifting hardware that either does not fall under an applicable standard or does not have criteria for operation or inspection, at not less than 100 percent and not more than 125 percent of rated capacity, unless otherwise recommended by the manufacturer or a qualified person.
  • Cranes. 29 CFR 1910.179(k)(2) states that test loads "shall not be more than 125 percent of the rated load unless otherwise recommended by the manufacturer". That sentence governs the rated load test of an overhead or gantry crane, not the test of a device hung from it.

By engineering reasoning, the construction rule and the Navy table give a test load, DOE gives a band, and the crane rule gives a ceiling. A specification that says only "proof test to 125 percent" leaves open which rule governs and whether 125 is a target, a minimum, or a maximum (29 CFR 1926.251, paragraph a.4; NAVFAC P-307, 2025, Table 14-1; DOE-STD-1090-2020, §13.1 and §13.10.2; OSHA 29 CFR 1910.179-2016, paragraph k.2).

ASME B30.20 covers below-the-hook lifting devices. The ANSI Blog reports that its 2025 edition updated the method to load test lifting devices; the post does not say what changed (ASME B30.20-2025; Kelechava 2025, ANSI Blog).

Is a 125 percent proof test a federal requirement outside construction?​

Not in general industry, among the federal rules cited here. Of those rules, the construction rule sets 125 percent for special custom design lifting accessories, and the longshoring rule described below sets it only for special stevedoring gear up to 20 short tons and for intermodal container spreaders. NASA-STD-8719.9C states that there are no OSHA regulations specifically addressing below-the-hook lifting devices; that is NASA's statement, and it does not mention the construction rule above. OSHA's own general-industry letter on the point, from 1977, concerned a special alloy steel chain lifting device:

  • 29 CFR 1910.184(e), on alloy steel chain slings, "does not address special alloy steel chain lifting devices", the strength of which depends upon components other than commonly used stock items.
  • When the employer in general industry designs and manufactures such a device, composed of special components such as spreader bars, "accepted engineering practices or other OSHA standards may be used as guides for proof testing the device as a unit."

The letter sets no percentage, and "may be used as guides" is permission, not a requirement. It also cites the longshoring rule as it read in 1977; the current text is 1918.61(f) and its Table A.

The current longshoring rule shows that 125 percent is not a universal multiple. 29 CFR 1918.61(f) requires special stevedoring gear provided by the employer, the strength of which depends upon components other than commonly used stock items such as shackles, ropes, or chains, to be inspected and tested as a unit before initial use. Paragraph (f)(1), which covers gear with a safe working load greater than five short tons, adds that any special stevedoring gear that suffers damage necessitating structural repair is inspected and retested after repair and before being returned to service. Its Table A sets the proof load by safe working load:

Safe working loadProof load
Up to 20 short tons25 percent in excess
From 20 through 50 short tons5 short tons in excess
Over 50 short tons10 percent in excess

By simple arithmetic, the margin falls from 125 percent at 20 short tons to 110 percent at 50 short tons. Paragraph (g) tests intermodal container spreaders that are not part of ship's gear before initial use to a proof load 25 percent greater than rated capacity, and paragraph (h) repeats the proof load test every four years for covered gear with a safe working load above five short tons (NASA-STD-8719.9C, 2024, §13.1.3; OSHA Standard Interpretation, May 3, 1977; 29 CFR 1918.61, paragraphs f, g, and h).

Which fixtures does the construction rule cover?​

The rule's words are "special custom design", and OSHA's letters set the boundary case by case, for construction work:

  • Not a stock item. If a grab, hook, clamp, or other lifting accessory is not a regularly manufactured or produced item, it is deemed a special custom design, and that holds for a custom-made lifting beam designed by a registered professional engineer and made under quality controls — 2003 letter.
  • Mass production. If a manufacturer mass-produces accessories that are all of the same design, the standard does not apply to them; if each unit is of a different design, the marking and proof-testing requirement applies to each one, even from a single manufacturer — August 2002 letter. Manufactured, non-custom lifting beams need not be proof-tested or marked under (a)(4) — 2004 letter.
  • Job-specific beams. OSHA does not provide a definition of special custom design. Wind-turbine lifting beams designed for the sole purpose of hoisting components of a particular turbine, whose materials and fabrication conditions can vary from job to job, are special custom designs, and each must be proof-tested. There is no exact number of beams that makes them mass-produced, so each of more than 400 beams fabricated at once must still be proof tested. OSHA added that "it could be considered a de minimis violation of § 1926.251(a)(4)" if industry-recognized acceptance sampling methods, such as the ISO 2859 series or ANSI/ASQC Z1.4-2008 and Z1.9-2008, are implemented and used to confirm the beams' specifications and safety based on the size of the batches produced — 2012 letter.
  • Supplier and life cycle. The rule applies to custom lifting accessories used in a construction activity "irrespective of who supplies the devices", and a shipping frame that lifts its tube bundle and is scrapped after installation is still covered: the standard "does not differentiate among custom-design lifting accessories by length of life cycle" — June 2002 letter.

In the 2012 letter's words, de minimis violations are violations of standards which have no direct or immediate relationship to safety or health. By engineering reasoning, a fabricator building one-off beams for a construction site should plan one proof test per beam, because the sampling route was written for batches (OSHA Standard Interpretation, July 7, 2003; OSHA Standard Interpretation, August 15, 2002; OSHA Standard Interpretation, February 9, 2004; OSHA Standard Interpretation, June 8, 2012; OSHA Standard Interpretation, June 14, 2002).

Can calculations or a professional engineer's stamp replace the proof test?​

Under the construction rule, no. OSHA wrote in June 2002 that the provision "does not permit calculations to be used in place of proof testing." In 2003, asked whether skipping the test on a beam made under quality controls, with engineering computations signed by a registered professional engineer, would be a de minimis violation, OSHA answered no: "Quality control and engineering computation documentation are not substitutes for assuring the performance of custom design lifting accessories through the required proof-test."

OSHA addressed one case where a test may be infeasible. For a shipping frame completed only as its tube bundle was built, it wrote that "the next most protective action must be taken", and that this may consist of steps such as proof-testing a used assembly and comparing the results with the calculated load capacity, safety factors in excess of what the standard requires, appropriate manufacturing controls, and sampling methodologies.

Agency programs draw their own lines:

  • NASA. Analysis may be substituted only for lifting interfaces permanently attached to the load, with approval of the Center's Lifting Devices and Equipment Manager (LDEM), documented rationale, and an LDEM finding of no increase in risk.
  • Navy. Where it is not practical to test locally fabricated special rigging gear, such as non-standard eyebolts made for a particular application, P-307 requires the activity engineering organization to approve its use.

ASME's page for BTH-1-2023 lists clarified requirements to establish the rated load of a lifting device by calculation among the edition's changes; the page does not describe that as a substitute for a load test. By engineering reasoning, the calculation and the test answer different questions: the calculation sets the rating, and the test checks the material, the construction, and the workmanship of the device that was actually built (OSHA Standard Interpretation, June 14, 2002; OSHA Standard Interpretation, July 7, 2003; NASA-STD-8719.9C, 2024, §13.3.2.4; NAVFAC P-307, 2025, §14.4.1; ASME BTH-1-2023).

When does a proof-tested fixture have to be tested again?​

The triggers depend on the program:

  • Construction. After a 125 percent proof test, the standard "does not require additional tests prior to each use". If the accessory undergoes changes that affect its safe working load, including changes during repair or replacement, it must be tested and marked again; a device that has been intentionally or inadvertently changed or modified "essentially becomes a different custom-design lifting accessory".
  • Construction, field reassembly. A factory-tested strongback shipped disassembled, with its nuts, bolts, washers, and pins replaced by similar parts, need not be retested after reassembly on site under a factory representative if all four conditions are met: reassembly follows the manufacturer's specifications and procedures; the parts suit the manufacture, disassembly, shipment, reassembly, and use described, with re-used original parts suited to the added stresses; all parts are inspected for diminished capacity; and quality control for the new minor parts is at least equal to that for the originals. OSHA did not address repeated disassembly cycles. A re-test is required if a part must be repaired or replaced because of breakage, damage, or evidence of diminished capacity.
  • NASA. A proof load test is required before first use of new lifting devices and equipment, before return to service after repairs or modifications that affect load holding capability or load-bearing components, such as welding on components in the load path, and after wire ropes or load chains are replaced. Below-the-hook devices also take a periodic load test at 0.95 to 1.00 times rated capacity within one year before use in a NASA Critical lift, unless the LDEM has approved them as non-load-test devices on documented rationale with no increase in risk. A proof load test satisfies the periodic test for that cycle.
  • Navy. Table 14-1 lists no periodic load test for below-the-hook devices in general, except that devices with rated loads greater than 10,000 pounds used in cargo transfer are load tested every four years. Plate clamps, vacuum lifters, and both magnetic lifter types are load tested annually.
  • DOE. Miscellaneous lifting devices are load-tested before initial use, including those whose load-sustaining parts have been modified, replaced, or repaired, and a re-rated device is tested again.

UTEC Industrial performs factory acceptance testing and on-site commissioning, the two points at which a fixture shipped in pieces can be checked against conditions like OSHA's four (OSHA Standard Interpretation, August 15, 2002; OSHA Standard Interpretation, June 14, 2002; OSHA Standard Interpretation, February 25, 2003; NASA-STD-8719.9C, 2024, §4.5.4, §4.5.5, §13.3.3.2, §13.3.3.6, and §13.3.4.1; NAVFAC P-307, 2025, Table 14-1; DOE-STD-1090-2020, §13.4.2 and §13.10.1).

How do agency programs set the test load, hold time, and tolerance?​

The Navy writes its fixture test out in detail. NAVFAC P-307 §14.4.1 requires:

  • an initial load test that the equipment withstands for a minimum of two minutes (10 minutes for hoists, winches, cranes, and crane structures) with no permanent deformation;
  • a nominal test load from Table 14-1, expressed as a percentage of the rated load established by the OEM or the activity engineering organization;
  • an actual test load of +5/−0 percent of the nominal, except for cranes, crane structures, hoists and winches, portable floor cranes, portable gantries and A-frames, and trolleys, which take +0/−5 percent;
  • acceptance of a supplier's certificate of load (proof) test, stating the actual test load and test duration, if those meet or exceed the requirements;
  • where the OEM does not permit testing at the table percentage, a reduced rated load, such that the OEM's allowed test load serves as the load test value.

For illustration, a lifting beam rated at 20,000 lb takes a nominal Navy test load of 25,000 lb, and the +5/−0 tolerance puts the actual load between 25,000 and 26,250 lb.

NASA writes the test by reference. For below-the-hook devices, the proof load test is as specified in the applicable ASME standard (B30.20 or B30.26), and for components or subcomponents as specified in their B30 standard or as recommended by the designer with LDEM concurrence. For all load tests, the load should be held long enough for dynamics to be dampened out or for a duration determined by the manufacturer. NASA's §13.3.2.1 sets a factor of 1.95 to 2.00 times rated capacity for NASA Critical lifting devices in that section, "except as specified in this section". A note to that clause sends below-the-hook devices to §13.3.2.6, which covers load positioning devices; the below-the-hook clause itself is §13.3.2.5. In UTEC Industrial's reading, that factor is not the below-the-hook test load.

DOE-STD-1090-2020 calls for all rigging equipment used in critical lifts, including below-the-hook devices, to be proof load tested in accordance with applicable ASME standards (NAVFAC P-307, 2025, §14.4.1 and Table 14-1; NASA-STD-8719.9C, 2024, §13.3.1.4, §13.3.2.1, and §13.3.2.5; DOE-STD-1090-2020, §2.2.5).

How is the test load weighed, configured, and rigged?​

The result depends on knowing the test load. For construction, OSHA wrote in 2004 that the standard does not specify how to determine the test weight, and any method "that can be reasonably expected to yield sufficiently accurate and reliable data" may be used. A weight calculated from an I-beam's measured dimensions and manufacturer or published weight tables is acceptable; a generator whose weight was determined by "guesstimate" is not, although its weight from the manufacturer would be. Certified test weights are not required, but the weight must be determined through accurate and reliable means.

The Navy sets accuracy rules where test weights are used for rigging gear. Each weight is marked with a unique identification number and its weight in pounds, taken from the scale, and solid weights are measured with calibrated equipment traceable to NIST with a minimum accuracy of ±2 percent.

Configuration also matters:

  • Assemblies. NASA tests a device made of more than one sling or rigging hardware component as an assembly, individually, or both, "as dictated by worst case stress and stability considerations", and an assembly test is based on the rated load of the assembly.
  • Multiple configurations. P-307 tests a below-the-hook device with multiple configurations in the one that imposes the greatest stress on the device. For modular devices, such as modular spreaders with intermediate compression sections, an ancillary equipment procedure (AEP) developed by the activity engineering organization and approved by the weight handling program manager or certifying official may preclude multiple load tests.
  • Adjustable and modular spreaders. The ANSI Blog reports that B30.20-2025 now addresses adjustable and modular spreader bars and clamps. The expected effect is that an adjustable or modular spreader is load tested in the configuration or configurations its rating covers.

By engineering reasoning, a fixture with an adjustable pick point is tested with the pick at the position that loads it hardest, and that position is written into the test report (OSHA Standard Interpretation, February 9, 2004; NAVFAC P-307, 2025, §4.7.1.1 and §14.9.1; NASA-STD-8719.9C, 2024, §13.3.1.2; Kelechava 2025, ANSI Blog; ASME B30.20-2025).

Can the plant crane be used to proof-test a fixture?​

Yes, within limits OSHA set for general industry in a 1994 letter under 29 CFR 1910.179(k). Using the crane for rated load testing of a below-the-hook device may be undertaken:

  1. as often as necessary, provided that the total weight on the hook does not exceed 100 percent of the crane's rated load; or
  2. no more than once between each periodic crane inspection required by 1910.179(j)(1)(ii)(b) and (j)(3), when the total weight on the hook exceeds 100 percent but does not exceed 125 percent of the crane's rated load.

OSHA "highly recommends" other acceptable methods, such as higher-rated cranes that stay within their rated capacity when testing below-the-hook devices. NASA's conditions for using a crane to load-test lifting fixtures, including a load measuring device in the lifting assembly and a 50 percent cap on the measured load in the cases NASA lists, are covered in Positioning Cranes vs. Standard Overhead Cranes for Precision Lifts.

A worked illustration shows how the hook load adds up. Assume a fixture rated at 30,000 lb that weighs 4,000 lb, tested at 125 percent with test weights hung below it, and 500 lb of rigging between the hook and the fixture:

  • Test load: 1.25 × 30,000 lb = 37,500 lb.
  • Total on the hook: 37,500 + 4,000 + 500 = 42,000 lb.
  • A crane rated at 40,000 lb carries 105 percent of its rating, which falls in OSHA's second case: once between periodic crane inspections.
  • A crane rated at 42,000 lb or more stays in the first case.

Counting the fixture and rigging in "total weight on the hook" is UTEC Industrial's reading of the letter's phrase; the letter does not itemize it. The figures are illustrative, not a rating (OSHA Standard Interpretation, August 8, 1994; OSHA 29 CFR 1910.179-2016, paragraph k.2; NASA-STD-8719.9C, 2024, §5.5.2.1).

What does a passed proof test prove, and what does it leave open?​

NASA's definitions state the purpose. A proof load is the load "applied to verify material strength, construction, and workmanship" when performing a proof load test, a load NASA notes typically exceeds the rated load, and a proof load test is "A static load test performed prior to first use, after major modification of the load path, or at other prescribed times." OSHA describes the construction rule's purpose as ensuring "that the design and construction of a custom lifting device is sufficient to meet its intended load rating". The Navy's pass criterion is no permanent deformation.

The test leaves three things open:

  • Fatigue. By engineering reasoning, a static test applied once says nothing direct about fatigue life. BTH-1 handles that through its service class, which, as Duerr described the then-new standard in 2008, "guides the design with respect to fatigue life assessment".
  • Damage from the test. By engineering reasoning, the proof load may be the largest load the device ever carries, and a weld inspection before and after the test separates fabrication defects from test damage. NASA's rule for surface NDT immediately after proof and periodic load tests is written for hooks on overhead cranes, mobile cranes, and NASA Critical lift hoists, not for below-the-hook device welds, and no public source cited here sets a post-test weld inspection for fixtures.
  • Condition in service. NASA's daily pre-use check of below-the-hook devices for cracks, deformations, gouges, galling, kinks, crushed areas, and corrosion is the field step that follows.

By engineering reasoning, the upstream steps decide what the test finds. Weld quality and residual stress are set in fabrication and stress relief, as described in Stress Relief for Machine Bases and Frames Before Final Machining. UTEC Industrial inspects welded structures with NDT and CMM (NASA-STD-8719.9C, 2024, §3.2, §12.3.3, and §13.4.4; OSHA Standard Interpretation, February 25, 2003; NAVFAC P-307, 2025, §14.4.1; Duerr 2008, pp. 43-47).

How do load sensing and controls support the test?​

The test record is a measurement, and the sensing that makes it belongs in the test plan:

  • Load measurement. NASA defines a load measuring device as a device below the hook used to indicate the weight of the item being lifted, such as a load cell or dynamometer. Its periodic load test includes an annual calibration per ASME B30.26. The Navy calibrates and marks portable load indicating devices per the activity's calibration program and the OEM's recommendations.
  • Expected value. A JPL lesson recommends that procedures record the expected load-cell reading and that someone be assigned throughout the lift to observe the load cell and call out the numbers. By engineering reasoning, the same discipline applied to a proof test catches a test load that is lighter or heavier than planned before the hold time starts.
  • Moving parts. For hoists, winches, trolleys, and other moving machinery, P-307 raises or lowers the test load through at least one revolution of all moving parts. By engineering reasoning, a powered fixture, such as a rotator or a motorized clamp, should be cycled under load in the same way, with its interlocks and its loss-of-power state demonstrated with the load on.

The drives and logic that perform those checks are part of the fixture's controls. UTEC Industrial is a Rockwell Automation Recognized System Integrator, and its controls work covers Allen-Bradley ControlLogix and CompactLogix PLCs, VFD and servo drives, EtherNet/IP networks, and UL 508A panel building (NASA-STD-8719.9C, 2024, §3.2 and §13.3.3.5; NAVFAC P-307, 2025, §14.4.1 and Table 14-1; NASA JPL 2011, LLIS Lesson No. 6216).

What records and markings should a proof-tested fixture carry?​

Each rule and program above asks for some trace of the rating or the test:

  • Construction marking. 1926.251(a)(4) requires custom accessories to be marked to indicate the safe working loads, and 1926.251(a)(2) requires rigging equipment to carry permanently affixed, legible identification markings, as prescribed by the manufacturer, that indicate the recommended safe working load.
  • Foreign test records. OSHA accepts proof-test documentation from outside the US for a construction beam that is uniquely identifiable by a serial number referenced on the documentation and proof tested to 125 percent of the desired working load, provided the testing followed generally accepted international standards such as EN 13155.
  • Navy records. Except as P-307 notes in §14.8 and §14.11, initial and periodic inspections and load tests are documented for each piece of applicable equipment, and a supplier's certificate states the actual test load and duration.
  • DOE records. For miscellaneous lifting devices, the inspector furnishes a written report showing the test procedures and confirming the adequacy of repairs or alterations, kept on file and readily available. DOE's identification-number rule for devices that cannot be marked is covered in the positioning-crane article.
  • NASA tags. Non-load-test devices are marked conspicuously as such, and after each periodic inspection each gets a durable tag stating the next required periodic inspection date or the inspection expiration date.
  • B30.20 marking. B30.20 requires the rated load to be marked on the device, and the ANSI Blog reports that the 2025 edition adds an appendix on marking devices with more than one rated load.

By engineering reasoning, a complete test record names the device's serial number, its rated load and configuration, the test load and how it was weighed, the hold time, the result, the inspection before and after, and the rule it satisfies. Records like these are what the MGSE acceptance package and a turnover fixture's commissioning are built from (29 CFR 1926.251, paragraphs a.2 and a.4; OSHA Standard Interpretation, June 8, 2012; NAVFAC P-307, 2025, §14.2 and §14.4.1; DOE-STD-1090-2020, §13.10.3; NASA-STD-8719.9C, 2024, §13.7.2–13.7.3; ASME B30.20-2025; Kelechava 2025, ANSI Blog).

Related Articles

References​

  • 29 CFR 1926.251: Rigging Equipment for Material Handling. Occupational Safety and Health Administration, 2012.
  • ASME B30.20-2025: Below-the-Hook Lifting Devices. ASME, 2025.
  • Kelechava, B. ASME B30.20-2025: Below-the-Hook Lifting Devices. The ANSI Blog, American National Standards Institute, 2025.
  • NAVFAC P-307: Weight Handling Program Management. Naval Facilities Engineering Systems Command, 2025.
  • DOE-STD-1090-2020: Hoisting and Rigging. U.S. Department of Energy, 2020.
  • OSHA 29 CFR 1910.179-2016: Overhead and Gantry Cranes. U.S. Department of Labor, 2016.
  • NASA-STD-8719.9C: Lifting Standard. National Aeronautics and Space Administration, 2024.
  • OSHA Standard Interpretation: Proof testing, as a unit, certain types of alloy steel chain lifting devices. Occupational Safety and Health Administration, 1977.
  • 29 CFR 1918.61: General (Gear and Equipment for Rigging and Materials Handling, Safety and Health Regulations for Longshoring). Occupational Safety and Health Administration, 2000.
  • OSHA Standard Interpretation: Marking and proof-testing requirements for special custom-designed lifting accessories. Occupational Safety and Health Administration, 2003.
  • OSHA Standard Interpretation: Rigging equipment for material handling; custom-designed accessories. Occupational Safety and Health Administration, 2002.
  • OSHA Standard Interpretation: Requirements for load-testing and marking of special custom-design rigging accessories; applicability of ASME standards. Occupational Safety and Health Administration, 2004.
  • OSHA Standard Interpretation: Proof testing of lifting beams used to lift wind turbine components. Occupational Safety and Health Administration, 2012.
  • OSHA Standard Interpretation: Custom-designed lifting accessories must be proof-tested and marked before being deployed for use and after repair or replacement. Occupational Safety and Health Administration, 2002.
  • ASME BTH-1-2023: Design of Below-the-Hook Lifting Devices. ASME, 2023.
  • OSHA Standard Interpretation: Retesting of reassembled lifting accessories if original manufacturing controls are ensured; retesting requirement if repair/replacement of parts due to breakage, damage, or evidence of diminished capacity. Occupational Safety and Health Administration, 2003.
  • OSHA Standard Interpretation: A crane may be used for rated load testing of below-the-hook lifting device provided the test does not exceed 125% for the crane's rated load. Occupational Safety and Health Administration, 1994.
  • Duerr, D. (2008). "Design Category and Service Class Selection for Below-the-Hook Lifting Devices." Practice Periodical on Structural Design and Construction, 13(2), 43-47.
  • NASA Jet Propulsion Laboratory. MSL Mobility Assembly Lift Mishap, Lesson No. 6216. NASA Lessons Learned Information System, 2011.

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