PROJECT DESCRIPTION:
Kallari Craft Association Competition Narrative
Our goal is to collaborate with the Kallari Association and help them achieve economic and artistic success. We bring a unique blend of experts and experienced resources to the Kallari cooperative to assist in solving the myriad of issues they may face in expanding their chocolate and craft market as well as developing a community center and tourist attraction. Given our experience in chocolate manufacturing, production facility planning and construction, we realize that the Kallari Chocolate makers have their own preferred methods and equipment that will ultimately guide us both as designers as well as resource asset managers. Our team includes not only the traditional planning experts of architects, Landscape architects, LEED and environmental sustainability specialists, civil engineers, micro-hydroelectric systems operators, computer technology and internet professionals, but also marketing and branding development experts embedded in our business plan team (see Supplemental Business Plan Submission), project management consultants, and nongovernment organization (NGO) representatives experienced in bridging cultural and international gaps both in Ecuador and world wide. Our hope is that our synergistic efforts have yielded a project of greater cohesiveness and ultimate feasibility than would otherwise have been developed, and that we are further able to capitalize on collaborative efforts directly with the Kallari Craft Association and other volunteers. This belief in collaboration and the desire to help the Kallari Association achieve their dreams is the foundation of our team and our proposal for the project.
The narrative is organized into the following major sections; General Architectural and Planning Concepts, Program Assumptions and Descriptions, Sustainable Development Strategies, and Computer and Internet Technology
General Architectural and Planning Concepts
The site plan is developed to work with the existing topography and significant
slopes, facilitating vehicular access while celebrating the path of water and views
of the majestic river valley. The entry point to the site serves as the gateway for
public visitors to the chocolate factory and craft retail sales area. It also opens to
an adjacent plaza serving the association Learning Center, where the Kallari can
gather throughout the week for various community activities, meetings, classes,
conferences, etc. This single entry allows a general access control point both for
potential entrance fee collection as well as direct access to the chocolate retail
area on a visitors way in and out. The rest of the retail area itself cascades down
a terraced plaza of Kallari craft booths northward to the larger community
gathering spaces and buildings, the Cafe, and the Botanical Garden, with private
community and residential buildings nestled into the southern portion of the site.
The overall concept is developed around sustainability as an integral aspect of the community, with one of the most visible example being site water collection and use along with celebration of living roofs over the largest structure of the factory and admin building, limiting runoff into the river and minimizing visual impact on the site. This announces to visitors that the Kallari Association and community center itself is focused on environmental stewardship at this site as they are with their cacao farms. Water is exposed along the terraces and plazas, and is envisioned to be used as grey water for various functions (see Sustainability Strategies). The layout allows the easiest site access and exit scheme, with the driveway and major construction parallel to the slope, with buried retaining wall structures to aid in temperature control and minimize exposed surface grading. We envision a center of lively community activities, varying and evolving as the community grows, enhanced by the intersection of craft plaza and pathway, community and visitor. Simultaneously, we realized that there are also areas where privacy from the more public activities is desirable which is achieved through site location and relative grade changes.
Major materials used include gabion rockery retaining walls which incorporates site collected rocks in either steel or bamboo cage material to form retaining walls, regionally harvested Guadua Timber Bamboo structural posts and site assembled trusses, thatch roof, plaster and bamboo solid wall panels, bamboo and grass matte moveable panels, and locally made textile/tent roofs. Conditioned spaces are limited as required, with natural light and ventilation maximized through application of skylights, borrowed light, and translucent tent roofing. The vast majority of materials could be locally or Kallari made and assembled, with limited readily available corrugated steel roof and connectors. We also envision the compound will likely be built in phases, growing and expanding with the community needs over generations. All major structural elements have been conceived around locally available materials and familiar methods. While some of the longer span trusses will require some engineering oversight, they are repetitive and scalable in nature and application.
There are essentially three (3) building types, identified by roof form, which create a language for the community center structures with a vocabulary of materials and methods associated. These are 1) living roof, 2) thatch, and 3) tent textile/fabric. The sloped site suggests and requires retaining structures in some locations, which is achieved through Gabion wall technology, using galvanized steel caging where below grade, and bamboo caging where above grade and protected. The gabion walls are plaster finished where conditioned space and insect control are required and left natural to allow ventilation wherever appropriate. Structures such at the Factory, Administration Building and Learning Center require varying degrees of conditioning and security, and thus are built of either the long span flat roof trussed living roof, or thatch roof, with thin plastered bamboo wall panels. These structures are traditional forms, with modern improvements to facilitate security and conditioning. We also recognize a need to provide flexibility for immediate use as well as long term growth. Given the mild climate, many of the gathering spaces may need only sun and rain shelter, and while thatch structures do provide this, they are relatively heavy and limit natural light. Our proposal recommends these structures be natural (bee) waxed textile/fabric tents over scalable site-built bamboo truss systems. The textiles could easily be made and maintained by the Kallari craftspeople, thus fostering continued self-reliance, keeping ongoing maintenance costs under control while providing work for the Kallari tradespeople themselves.
As we reviewed and conceived of the various functions of the facility compound, we drew upon our South American cultural heritage within our own architectural firm (Bolivia and Peru), but also from NGO representatives historically active in Ecuador and interested in the Kallari Association project, as well as international chocolate grower and industry representatives who currently work with the Kallari. Our proposal diverges from the program on occasion, as our understanding of it became informed by our investigations and information gathered when we were unable to get direct responses. We see these as options and opportunities to capitalize on flexibility and multi-use relationships within the program that may not have been fully explored or considered. In the final program analysis, these aspects may or may not prove valuable, but we thought them worthy of consideration. One such divergence occurs around the café, which we envision serving not only families of visitors out for their weekend “dia de campo” (day in the country), but also with the kitchen serving as the other community center activities.
Program Assumptions and Descriptions
Factory
Building type and material is living roof over long span bamboo trusses,
plastered gabion walls and bamboo panels. We have enhanced the factory
process and production line with optional and additional equipment as well as
temperature, humidity and particulate control measures. Factory optimization
and cleanliness is paramount to consistent product quality and protection of
finished goods. Simple tried and true methods can foster clean production
environments, such as exhaust/fan pressurization control, screened natural
ventilation and borrowed light, production path flow, and proper door swing
orientation to support pressurization. Conditioning as needed could be provided
via the micro hydro-electric heat pump or direct water transfer cooling (see
Sustainability Strategies).
Exhaust and intake fans can be can be run by direct solar convection (alternate blades painted black & white) or may be on the solar/hydroelectric power system. It is important to allow flexibility so the system can be properly balanced to allow roasters and cyclones to function properly. Factory flow and temperature control for both products and people needs to be considered, along with limiting cross path contamination. Our proposal varies somewhat from program information given, based on ‘assumed/projected’ methods and equipment, but will need to be verified with the Kallari Chocolate maker’s preferred methods and practices. While the above are simple techniques, they are just a few examples of the real world food and chocolate production knowledge and expertise we look forward to sharing with the Kallari Association.
Factory rooms and equipment:
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• Shipping & Receiving w/weather protected Loading Dock- open to ambient
air
• Cleaning & Bean Storage Room w/ Exhaust Fan, Cleaner/Destoner, Filter banks, and Cyclones to contain contaminants- air pressure (-1)
• Roasting & Winnowing Room w/ Cyclone and connection to Filter Banks and room for bean transfer can storage- air pressure (+1)
• Tour Hopper for tour education, assembly, access control could be open to ambient air- air pressure (+0)
• Kitchen & Lunch Room could be open to ambient air- air pressure (+0)
• Melanguer, Ball Mill, Macintyre Refiner Conche w/ Butter Melting Station, Tank, & Butter Press in warm room, desired temperature approx 85F/29Cair pressure (+2)
• Holding Tanks, Tempering Unit, Depositor, Cooling Tunnel, desired temperature approx 75F/22C- air pressure (+3)
• Packaging and Food storage Room w/ work tables and Wrapper, desired temperature approx 68F/20C w/ 60% relative humidity- air pressure (+4)
Building type and material is living roof over long span bamboo trusses, plastered gabion walls and bamboo panels. Attributes include:
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• Composting toilets
• Conditioned Computer/Server areas
• View to the factory floor
• Adjacent to site entry control point and retail sales area
• Retail order and graphic printing and filing
Building type and material is thatch roof over bamboo truss/framing with both bamboo and plastered bamboo fixed and operable panels. Attributes include:
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• Centralized "community bulletin board"
• place for adult and child classes and activities
• place for internet research and internet access for community members
• teacher office and storage secured from classroom and multipurpose space
• The computer lab and graphics studio originally programmed for the administration building were relocated to promote multiple user and community accessibility
• place for chocolate marketing research (i.e. web searching to find out what current trends are)
• computer lab to be conditioned, wall infill to be plastered bamboo panels
• multipurpose classroom and library and to be secure but not conditioned
• sliding wall panels at multipurpose room opened for additional flexibility, allowing indoor/outdoor space
• folding door/wall panels between classroom and multipurpose room for larger groups
• plaza landscaping and water features delineate public and non-tourist zones
• connection between gallery and learning center
• connection between learning center and private residential area
Building type and material is thatch roof over bamboo truss/framing with both bamboo and plastered bamboo fixed and operable panels. Attributes include:
-
• limit public access with operable wall/door panels
• security for cultural artifacts
• multi-use gathering and meeting room for community organizations, meetings, and social gatherings of all kinds
• Kallari cultural history and craft display
Building type and material is fabric/textile tent structure over bamboo trusses.
Attributes include:
-
• adjacent to Site Entry control point and Administration for control and
security of some retail items
• on path of egress and exit for maximize sales and retail opportunity
• tent structure provides ample natural light with supplemental point retail focus lighting
• relates to craft market booths and terraced plaza
• Chocolate tasting room
• Café
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• tent structure creates an open air seating structure while maximizing
views and natural ventilation
• Living roof provides noncombustible noise control and provides enclosure and security of valuables
• open space also allows for flexibility of use by community and guests
• incorporating a green roof and a more solid kitchen space to minimize heat gain within and reduce noise pollution
• living roof maintains the visual site lines and consistency from the site entry plaza
Building type and material is thatch roof over bamboo framing with both bamboo and plastered bamboo fixed and operable panels. Attributes include:
-
• departure from the program in separated the housing from the factory to
create a more village/ community area. The residence area consists of
bunk houses and a wash facility with laundry and bathroom.
• buildings are traditional and easily built with local techniques and materials.
• bunk houses are lifted off of the ground to minimize site impact and spaced to allow for maximum natural ventilation.
• village concept is easily expandable for future housing needs
• familiar housing form
Building type and material is fabric/textile tent structure over bamboo framing. Attributes include:
-
• adjacent to entry plaza and retail
• located along site terraced plaza and on path to factory tour hopper/starting location
• expansion provided along base of high factory wall
• opens to gathering space for special event/festival and community expansion as regional tourist destination
• flexibility to expand as desired for season, market, sellers, etc.
Attributes include:
-
• located at lower level of site to maximize opportunities for collected water
use
• adjacent to more natural form of water feature
• overlooking river
• adjacent to café to celebrate site-grown foods served as well as those used in craft dies and materials
The platform is conceived as a portable satellite learning center made on a readily available truck/trailer platform. Attributes include:
-
• self sufficient solar charging
• “Web-mobile” based on “bookmobile” concept
• Accessible to multiple children at once and remote community at large
• secure and weatherproof
Successful sustainable design requires a holistic approach to building and site. As in nature, the relationships that exist between location and users may be challenges or utilized for mutual benefit. It is known that working against natural conditions requires more of everything: energy, materials and building systems. Informed by nature, we intend these structures to interact with the site as organisms rather than machines. Challenged to integrate with the local geography and climate, we considered foremost the pristine environment and biodiversity of the Napo Province. With an average rainfall of 2 meters, abundant water is just one of the many unique site features. The Amazon rainforest is a complex balance of relationships that must be preserved for the ecosystem to survive. These relationships are sensitive to human activity; however people have been living in the rainforest for centuries. Studying the traditional architecture of the Kichwa culture, we recognized their construction traditions are inherently sustainable. These building practices have evolved in response to their environment and available resources. The Kitchwa construction traditions will be enhanced with modern amenities as needed for chocolate production and information technology. By expanding upon familiar methods, local labor may be used to construct, operate and maintain the facility over time. Both the community and rainforest will benefit from employing multiple sustainable strategies for the Kallari Association facility.
Major Building Strategies Employed
1. Living roof
2. Rapidly renewable, local building materials
3. Certified wood products
4. Recycled-content building materials
5. Rainwater harvesting
6. Pervious paving materials
7. Storm water management strategies limit soil erosion
8. Solar power
9. Low-impact micro hydro-electric power
10. Passive ventilation
11. Natural day lighting
12. Innovative wastewater treatment
13. Salvaged glass
14. Passive heating and cooling
15. Solar hot water heating
16. Construction waste management diverts scraps away from landfill
17. Water efficient landscaping uses no potable water
18. Water efficient plumbing fixtures minimize potable water use
19. Low-emitting paints, adhesives and composite materials
20. High efficiency HVAC systems
21. Development strategies minimize site impact during construction
22. Development footprint integrates with hillside
23. Light pollution reduction strategies reduce impact on nocturnal habitat
24. Bicycle parking facility
25. Facility serves as an interpretive center for sustainable design
While comprehensive, our sustainable strategies for this facility focus on 4 main themes of efficiency; building materials, site strategies, water and energy. With LEED™ Gold certification in mind, a variety sustainable materials and methods have been selected for the construction of the Kallari facility. This facility has been designed to LEED V2.2 New Construction standards. The majority of credits pursued may be achieved by tangible strategies. Several additional credits would require additional analysis, calibration/verification of building systems and thermal comfort, and monitoring by third party consultants. These services would likely be required in order to achieve the equivalent of 39 credits required for LEED Gold certification. These services ideally would be donated by qualified consultants.
The majority of the building materials proposed for the Kallari facility are familiar and native to the region including regionally harvested Guadua Timber Bamboo. Requiring little transportation and manufacturing, these local materials are common to traditional construction and inherently sustainable. Examples are woven and bamboo panels and thatch roof; rapidly renewable materials and forms common to the Napo Province. After reviewing the specific needs of the Kallari Association, several unique qualities of space requirements were identified. For example, the chocolate factory requires large enclosed tall indoor spaces to accommodate equipment. Larger spaces require longer roof spans. Several modifications to traditional bamboo connections were required to provide long spans using a minimal amount of structure. In another variation, we propose a bamboo lath and plaster wall construction. These updated yet simple bamboo construction details ensure that local labor may be used for construction and long-term maintenance. Applying modified construction methods to other buildings on the site allow for innovative roof expressions; iconic gestures in sustainable design. To strengthen the destination experience, we incorporated the use of lightweight tent structures. Versatile yet simply constructed from bamboo and wax-treated fabric/textile, these structures are proposed for several public areas. These lively spaces offer flexibility, natural light and ventilation using environmentally-friendly yet durable materials made by the Kallari Craft Association members. Another subtle departure from traditional Kichwa construction is the use of Gabion “rock cage” walls. Essentially rocks enclosed a wire box; these durable modules are used to integrate the buildings with the natural geography. Gabions are proposed to be used for both earthwork and building applications filled with native rock material removed during necessary clearing of the actual site.
Not all building materials can be local or rapidly renewable. Wherever possible, we intend to employ recycled content and/or salvaged materials in lieu of “off the shelf” products. Spanning a wide spectrum, this class of materials includes fiberboard, steel and local salvaged materials. The use of wood and bamboo products from certified forest stewardship suppliers that support sustainable forestry practices are another responsible option. Recycled, reclaimed or FSC type certified alternatives all minimize the impact of using raw or finite natural resources.
To address the many characteristics of a rainforest site, we propose the use of various low-impact strategies which cooperate with the natural geography. The primary site challenges are the steep-sloped rainforest habitat and an abundance of water. In response, our stepped/linear plan bends with the contours and engages the site through terraces and retaining walls. Conforming to the natural grade and contours, the profile of buildings and landscape are minimized, both visually and physically. Site terracing minimizes unnecessary cut/fill earthwork and helps to control runoff and erosion. With 2 meters or more of annual rainfall, water is abundant most of the year. To address water surplus and use, various water strategies must be employed including:
• Oversized rainwater harvesting from roofs (cistern, sand filtration & gravity-fed plumbing)
• Storm water control though bio-swales, pervious paving and on-site infiltration
• Living roofs and native landscaping require no potable water
• Water-efficient plumbing fixtures (composting toilets/waterless urinals)
• Gray water from sinks and showers is treated naturally by vegetation and percolated on-site, recharging the local aquifer with clean water.
On a sloped site abutting a river, controlling soil erosion is imperative. Construction site boundaries and temporary erosion techniques minimize the disruption to the native ecosystems during construction. Restoring all disturbed native vegetation maintains the local habitat and further reduces erosion. Using strategically placed native shade trees will offer erosion control while aiding heating and cooling of buildings.
Considering the Kallari Association’s remote location, concerns about energy consumption and supply are justified. To rely solely upon grid power would be a mistake. Several forms of free, clean energy are available to the Kallari facility. Redundant power sources must be employed to guarantee operations continue regardless of the grid. By first reducing the energy consumption, we begin to solve the energy challenges. We intend to use flexible structures and passive strategies wherever possible. Through these energy-saving measures, we greatly decrease the power demands. These measures include: Thermal mass heating and cooling, operable wall panels for ventilation and day lighting, deep eaves for shade, gravity-fed plumbing, living roofs, locally produced recycled shredded textile/cotton insulation, compact fluorescent and LED lighting, highefficiency on-site-powered HVAC equipment, low-albedo roof and paving materials to reduce heat gain and landscaping oriented to provide shade. With these measures in place, we can predict the power consumption for normal operations and design our systems for maximum efficiency. To estimate the size of this system, we performed a few preliminary calculations. The anticipated load for the factory is as follows:
Anticipated Chocolate Factory Electrical Loads
| Average DC Load | Volts | Amps | Watts | Hrs./Day | WH/Day |
| Granite stone chocolate grinder | 24 | 40.0 | 960 | 8.0 | 7,680 |
| Inverter (for AC loads) | 24 | 19.0 | 456 | 11.0 | 5,016 |
| Chocolate temper kettle | 24 | 43.0 | 1,032 | 4.0 | 4,128 |
| 19 DC CF lights | 24 | 10.5 | 252 | 10.0 | 2,520 |
| 2 Vent fans | 24 | 5.0 | 30 | 24.0 | 3,600 |
| Cocoa bean winnower | 24 | 33.3 | 799 | 0.8 | 599 |
| Cocoa butter press | 24 | 4.0 | 96 | 2.0 | 192 |
| Mold cooling tunnel | 24 | 5.0 | 48 | 4.0 | 960 |
| Cocoa bean roaster | 12 | 5.0 | 60 | 2.0 | 120 |
| Chocolate mold vibrator | 12 | 1.5 | 18 | 3.0 | 54 |
| Total 24,869 WH (full load) |
After benefiting from the energy-saving measures, the factory will account for the largest portion of the electrical demand. Assuming the rest of the facility uses an additional 10% over the factory load, a rough estimate of required peak kilowatt hour demand is 27.3 kWH. This estimate assumes the unlikely scenario that all facility electrical equipment is operating at the same time. A reasonable operational factor of 80% yields an estimated demand of 21.9kWH. To meet this demand, on-site energy will be provided by multiple sources apart from grid power. Some strategies operate at peak efficiency during specific seasons, some only during the day. An example of such is solar power. With a $20,000 USD budget available for solar electric, this system will likely provide only a fraction of the total electricity needed for the facility. This budget will approximately afford a high quality 2 kW system. Ideally, additional solar equipment would be donated to the facility. Mounting the panels high on rotating poles, the panel direction may be adjusted for maximum efficiency. Elevating the solar array of the ground makes theft more difficult. The sun’s rays may also be used to heat hot water. We propose to harness this free energy using efficient evacuatedtube units for preheating water. Additional heating can be added with electric tankless water heaters. Cold water will be available from the buried collection tank, naturally chilled.
A more cost effective and productive system of low speed, low-impact microhydroelectric power generation is proposed to harness additional free energy. After careful consideration, a system has been selected that minimizes the impact to the river ecosystem. Based upon the photos of the river, this quantity may be generated through low-impact hydroelectric equipment. We propose to cantilever two side-by side Gorlov Helical Turbine systems at a suitable portion of the river. A proven low-impact system, it affords quiet and efficient hydroelectric power generation on-site. University of Michigan studies have verified the small pressure zone formed by the blade motion causes fish to swim around the turbine, similar to a rock in current. They can be installed with light weight locally built suspension frames limiting impact on rive bank and bottom surfaces. The blades spin at less than 100rpm (3/4 second per 3’ diameter revolution) virtually eliminating risk of impact damage to aquatic life. Very affordable, two (2) helical turbines and associated switch gear equipment, heat pump, and battery banks would cost approximately $20,000 USD. This price is equivalent to the solar budget and could be substituted in its place. The installed turbine cost is approximately under $5,000 USD and could be phased for cost control.
(See Kallari supplemental text for flow chart of the micro-hydroelectric generation and distribution system)
Generating in DCV is preferred, starting with one turbine/generator unit, and as the site and development expands adding more as required. Generating in DCV avoids complexities associated with ACV power including synchronizing the power waves of multiple generators. From the generators the line voltage flows to a load control center that will primarily power the DC panel, secondarily charge the DC battery bank, and tertiary dump to the cooling system. The batteries act as back-up to the DC panel, in case the turbines/generators need to be taken off line for service. From the DC panel all DC equipment motors are powered, as well as DC lighting, DC outlets, Heating equipment, heat pump(s), compressors and an inverter to produce AC voltage. The AC voltage is fed through a panel to power the remaining AC motors and auxiliary 110v outlets. The reason for providing both DC and AC power for motors and/or appliances are is that certain equipment/motors are not available in DC.
(See Kallari supplemental text for flow chart of the micro-hydroelectric generation and distribution system)
The electricity generated from solar and/or low-impact hydroelectric will be tied to a central battery bank. Excess power, generated 24hrs a day 7 days a week, by the micro-hydroelectric plant could power a heat pump for heating, cooling and humidity control as well as hot water for facilities and equipment. Surplus power may be potentially sold through net metering or other means. The local power grid and on-site Biodiesel generators are proposed as emergency backup power sources.
The Kallari Association facility has been designed to LEED New Construction standards with the intent to achieve the equivalent of LEED Gold certification. By using LEED as a framework for design, we have applied many sustainable strategies to the facility, serving both people and environment. Among the many purposes, we propose that the facility also serve as an interpretive center for sustainable design. Very few facilities on the planet could serve as a powerful example of the nexus of community, business and environment. Placing simple placards at each feature, visitors could take some of this consciousness home with them.
Internet and Computer Technology
After careful consideration of various options for the computer technology,
communications, and internet connectivity, our experts recommend the Kallari
focus on their primary chocolate production business to avoid operational pitfalls
and distraction from the primary goals. While Information Technology is
important it can be a distracting and energy intensive. Initially all web based
content would more appropriately be hosted and maintained by a service
company with a 24/7 capability and reliable broadband connection to the
Internet.
Web access for education needs to be accessible virtually on demand. The notion of a mobile technology facility creates an inherent conflict in that the information is taken away in the computer itself, unlike the “bookmobile” model which leaves the information behind. We suggest the mobile facilities be viewed as assets for trained staff who visit the outlying sites. If Internet access is desired in remote locations satellite access is probably the only viable network option, though cost and complexity need to be considered. Vehicle or generator power is likely to be required.
The primary form of computers should be notebooks. They consume less power, can be moved to the place of need, and can be more easily secured from theft. The exception would be the primary computer in the business area of the factory. Its role would be as a server to back up vital information from the portables, control access to the network connection, and host the business system of the factory.
Simple lead-acid storage batteries are the energy storage medium of choice due to their universal availability, longevity, and simplicity. Recharging systems are simple and can be installed in fixed locations powered by grid, hydro, and solar power generation systems. Portable PCs can be powered/recharged via simple inverters and/or regulators.
We suggest considering the IT equipment as the base of a pyramid of capabilities. A good foundation of reliable equipment, simple software, and trained staff is required to avoid the system ending up unused or in need of minor repairs in a closet. Simplicity should be the guiding principle.
(See Kallari supplemental text for a diagram of recommended approach to computer and internet technology development that allows the Kallari to grow into greater and ongoing responsibility)
(See Kallari supplemental text for a diagram describing the key relationships between technology, responsibility and skill advancement within the community)
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Sohbet