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Efficient pulley lagging is essential to maintain belt traction, extend pulley life, and ensure stable conveyor operation. Today, industries typically choose among three main solutions:

Rubber lagging
Ceramic lagging
Wear-plate lagging (e.g., D-Plate)

Each technology has specific benefits, limitations, and ideal application conditions.
Below is a thorough engineering comparison.

1. Rubber Lagging

✔ Advantages

Low initial cost
Good flexibility – absorbs small impacts
Good friction coefficient when new
Lightweight → Easy installation
Works for light to medium duty conveyors

✘ Limitations

Very poor abrasion resistance
Wears quickly with sharp, abrasive materials (clinker, iron ore, limestone)
Delamination risk is high due to adhesives (glue failure)
Sensitive to heat, oil, chemical attack
Loses friction rapidly → belt slippage increases energy consumption
Requires frequent re-lagging (6–12 months)

👍 Best For

Low-abrasion industries
Light material handling
Non-critical conveyors

👎 Not Suitable For

Cement industry (clinker, hot zones)
Mining (ore, rock impact)
Steelmaking (coke, sinter)
Power plants (fly ash, bottom ash)
Any system with high abrasion or high temperature

2. Ceramic Lagging (Rubber Backing + Embedded Ceramic Tiles)

✔ Advantages

Much higher wear resistance than rubber
Ceramic tile surface provides exceptionally high friction
Good performance for wet conditions
Reduces belt slippage effectively

✘ Limitations

Tiles can crack under impact from large rocks
Tiles may debond from the rubber matrix
Still relies on adhesives → delamination remains a risk
High local friction may cause belt surface wear
Not designed for very high temperature applications
More expensive than rubber

👍 Best For

Wet environments
Slippage control
Medium to high abrasion (not extreme)
Conditions where traction is the main concern

👎 Not Suitable For

Very high impact
Extreme abrasion
High-temperature pulleys
Environments where adhesive failure is common

3. Wear-Plate Lagging (Hardfaced Chromium-Carbide Overlay Plates)

(E.g., D-Plate Wear Lagging Using POP Technology)

✔ Advantages

Outstanding abrasion resistance (5–10× rubber)
Metallurgical bond → Zero delamination
Works in very high temperatures (400–600°C)
Resistant to:

abrasion
erosion
corrosion
impact
thermal cycling

Stable traction with cross-grid patterns
Extremely long service life (3–5+ years)
Low maintenance cost
High reliability in critical operations
Customizable alloy composition for specific wear conditions

✘ Limitations

Higher initial cost than rubber
Heavier → requires proper welding or bolting
Installation requires skilled technicians
Not designed to provide elastic cushioning (like rubber)

👍 Best For

Cement (clinker handling, high heat zones)
Mining (ore, rock, impact zones)
Steel mills (sinter, coke, slag)
Coal power plants (fly ash, coal handling)
Any 24/7, high-load, high-abrasion industrial conveyor

👎 Not Suitable For

Light-duty conveyors
Applications where elasticity or noise reduction is important

⭐ Overall Evaluation

Rubber Lagging

Suitable for light-duty, low-abrasion scenarios. Cheap at first—but expensive in the long term.

Ceramic Lagging

A good intermediate solution, especially for wet or slippery conditions.
Better traction than rubber but still limited by tile cracking and delamination.

Wear-Plate Lagging (D-Plate Type)

The most durable and reliable solution for medium to extreme conditions:

no delamination
excellent against abrasion and heat
predictable long-term performance
longest lifespan
lowest lifecycle cost

For industries facing continuous heavy wear, wear-plate lagging is the clear winner.

⭐ Conclusion: The Future of Pulley Lagging

Due to the increasing abrasion levels, higher production loads, and stricter uptime requirements, many plants have started phasing out rubber and ceramic lagging. Wear-plate lagging—especially advanced hardfaced products like D-Plate—is becoming the new global standard for pulley protection in high-duty operations.

It offers:

superior durability
predictable maintenance
significant cost savings
improved conveyor reliability
higher plant productivity

For mission-critical conveyors, the choice is no longer about cost per meter—it is about total cost of ownership (TCO), safety, and reliability.
And in all these aspects, wear-plate lagging stands clearly ahead.

Documents:

5. D-Plate Pulley lagging

6. KOVI Catalogue for powder specifications[/tintuc]

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In heavy industries—cement, mining, steel production, and coal-fired power—conveyor systems are the backbone of material handling. When the conveyor stops, the entire plant stops. And among all components, the pulley is one of the most critical yet most frequently compromised parts.

For decades, rubber lagging has been the default solution for protecting pulleys and improving friction. But in today’s high-abrasion environments, traditional rubber lagging is no longer able to keep up.

A new solution has emerged:
Wear-plate lagging, engineered from high-chromium, carbide-rich overlay materials such as D-Plate.
This technology is now rapidly replacing rubber lagging across the world.

This article explains why the shift is happening—and what advantages wear-plate lagging brings to modern industrial operations.

1. Why Rubber Lagging Fails in Modern Industrial Environments

Rubber lagging was sufficient in the past for moderate abrasion and predictable operating conditions. But today’s plants face:

higher material throughput
harder and more abrasive minerals
hotter operating temperatures
more frequent impact loading
stricter uptime requirements

Rubber simply cannot withstand these conditions. The most common failure modes include:

1.1 Abrasive Wear

Sharp clinker, iron ore, limestone, or coal particles grind and cut the rubber surface.
Wear accelerates with:

high belt tension
misalignment
high loading points
fine abrasive dust

1.2 Delamination

Because rubber relies on adhesives, heat and vibration eventually weaken the bonding layer.
One crack → moisture enters → the entire sheet detaches.

1.3 Thermal Degradation

Drive pulleys generate heat due to:

torque transfer
belt slippage
friction under load

Rubber hardens, cracks, and loses friction.

1.4 Chemical and Oil Damage

Common in steel and mining environments, chemicals penetrate the rubber matrix and compromise structural integrity.

The result:
Rubber lagging requires replacement every 6–12 months, causing downtime that costs far more than the lagging itself.

This is why industries are shifting to a stronger, more durable solution.

2. What Is Wear-Plate Lagging?

Wear-plate lagging uses hardfaced chromium-carbide overlay plates, welded or bolted directly onto the pulley shell.
The plates are engineered with:

a metallurgical bond
hardness up to 58–65 HRC
high carbide density
cross-hatch traction patterns
excellent heat resistance
minimal wear rate

Instead of a soft surface (rubber), the pulley is protected by a rigid, abrasion-proof armor layer.

Compared with rubber lagging, this solution lasts 5–10 times longer, depending on application.

3. Technical Advantages of Wear-Plate Lagging

3.1 Superior Abrasion Resistance

The hardfaced surface contains M₇C₃ carbides, among the hardest structures used in wear protection.
These carbides resist:

cutting
scratching
gouging
grinding

Even under continuous abrasive flow.

3.2 Zero Delamination

Wear plates bond through welding or bolting, eliminating adhesive layers.
No glue → no peeling.

3.3 High-Temperature Performance

Wear plates maintain integrity even at 400–600°C, making them ideal for:

clinker conveyors
sinter plants
steelmaking lines
hot-material transfer systems

Rubber cannot operate in these conditions.

3.4 Stable Traction Performance

Textured patterns (cross-grid or diamond pattern) maintain:

stable friction
consistent belt grip
reduced slippage

This improves energy efficiency and reduces belt wear.

3.5 Lower Life-Cycle Cost

Although initial cost is higher than rubber, wear plates last significantly longer and reduce:

downtime
re-lagging frequency
maintenance labor
emergency repairs

Total lifecycle cost can be reduced by up to 60–70% over a 4-year cycle.

4. Comparing Rubber Lagging vs Wear-Plate Lagging

5. Applications Across Industries

Wear-plate lagging is now widely used in:

5.1 Cement Industry

Raw material conveyors
Clinker cooler conveyors
Kiln feed systems

Cement plants report 3–5× longer pulley life after switching from rubber.

5.2 Mining & Quarrying

Ore transfer conveyors
Limestone and granite handling
High-impact feed chutes

In mining, rubber often tears early; wear plates remain stable.

5.3 Steelmaking

Coke conveyors
Sinter handling systems
Heat-intensive pulleys

Wear plates endure both abrasion and temperature.

5.4 Coal-Fired Power Plants

Fly ash conveyors
Coal handling systems
Bottom-ash transfer lines

Where fine ash rapidly grinds rubber away, wear plates excel.

6. Why D-Plate Wear Lagging Stands Out

D-Plate is engineered using BCC’s proprietary POP – Powder Overlay Process, which delivers:

highly controlled carbide formation
uniform hardness
low dilution (<8%)
excellent bonding strength
predictable wear performance

POP technology allows BCC to tailor:

alloy composition
layer thickness
surface pattern
impact resistance
thermal stability

This customization makes D-Plate suitable for a wide variety of pulley sizes and operating conditions.

7. Installation Options

7.1 Weld-On Lagging

Permanent bonding
Highest durability
Ideal for extreme environments

7.2 Bolt-On Modular Lagging

Faster installation
Replace only worn modules
Ideal for remote sites or limited downtime

8. Conclusion: A Modern Upgrade for Modern Heavy Industry

Rubber lagging was the right solution in the past—but industrial demands have changed.

Wear-plate lagging, especially with advanced technology like D-Plate, offers:

dramatically longer lifespan
consistent performance
reduced downtime
stronger ROI
safer operation

For plants facing high abrasion, high temperature, or heavy impact, switching to wear-plate lagging isn’t just an upgrade—it’s a new standard.

Below is fabrication procedure that BCC did for steel making plant.

Documents:

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Coal-fired power plants operate under extreme erosive and thermal conditions. Coal dust, ash particles and high-temperature gas flows rapidly wear down steel components, leading to performance loss and production instability.

D-Plate provides a dependable and long-lasting wear protection solution across all coal processing and boiler systems.

Applications in Power Plants

Boiler System

ID fan / PA fan housings
Coal mill wear plates
Venturi liners
Mill cones & orifices
Ash pump impellers and casings

Coal Handling System

Crusher starter plates
Coal mill rings
Transfer chute liners
Bulldozer bucket edges & tips

Why Power Plants Trust D-Plate

Strong resistance to coal and ash erosion
Excellent heat stability for boiler and duct applications
Reduces risk of fan imbalance and mill vibration
Extends lifecycle of critical systems
Can be repaired using D-Tech 3R onsite refurbishment

D-Plate enhances reliability, reduces failures, and supports cleaner, more efficient power generation.

Documents:

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Mining environments are defined by high impact, aggressive abrasion, uneven material loading and heavy shock. Wear components must withstand continuous rock flow, sharp edges, and high drop heights.

D-Plate, produced by BCC’s POP overlay technology, is engineered to outperform traditional wear plates in every critical mining application.

Common Mining Applications

Hopper and chute liners
Transfer points for conveyors
Crusher liners and breaker plates
Cyclone feed pipes
Vibratory feeder plates
Washer pipework bends, reducers & spools
Screen plates and deck liners
Reclaimer bucket liners and dozer blade edges

Why Mining Operations Prefer D-Plate

Outstanding abrasion resistance for ore, sand, coal and aggregates
Handles heavy impact and rock drop
Long service life even in high-velocity material flow
Decreases shutdown frequency and maintenance cost
Custom designs available for specialized equipment
Can be refurbished on-site with D-Tech 3R

D-Plate ensures safer, more stable and more efficient mining operations with superior long-term performance.

Documents:

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Steel manufacturing involves severe operating conditions: high temperatures, thermal shock, abrasive sinter and ore, and constant mechanical impact. Standard steel components fail quickly in such environments.

D-Plate provides a high-strength, metallurgically bonded wear surface designed specifically for the harsh realities of steel production.

Applications Across the Steel Production Chain

1. Sinter Plant

Ore loading systems
Sinter conveyor rollers
Suction boxes
Hot screening systems
Sinter cooler components

2. Gas Cleaning Systems

Bischof gas cleaning cones
Dust ducts and cracking units

3. Blast Furnace Operations

Coke sinter screening chutes
Skip hoist liners
Burden bunkers
Top bell and protection shells

4. Converter (BOF) & Refining Lines

Charging chutes
Slag handling liners
Alloy feeding funnels

Advantages for Steel Manufacturers

Superior resistance to abrasion and thermal shock
Suitable for areas with repeated temperature cycling
Stronger than cast white iron and traditional chrome carbide plates
Custom-made parts available through D-Parts program
Onsite hardfacing repair with D-Tech 3R

With D-Plate, steel plants achieve higher equipment performance, reduced downtime, and predictable operational stability.

Documents:

4. D-Plate100 - Testing reports
5. KOVI Catalogue for powder specifications

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Wear is one of the most persistent challenges in cement production. From raw material extraction to finish grinding, every stage involves continuous abrasion, impact, particle flow and high temperature. These factors quickly degrade steel components, cause unplanned shutdowns, and increase maintenance costs.

D-Plate, engineered using BCC’s proprietary POP – Powder Overlay Process, provides a high-performance solution for cement manufacturers seeking longer equipment lifetime and greater operational stability.

Key Applications in Cement Plants

1. Raw Material Extraction & Crushing

Crusher chutes and mixer hoppers
Transfer points and bucket elevator housings
Raw material silo and grab liners

2. Grinding & Drying

Ball mill inlet/outlet liners
Air chamber rings
Dust exhaust fans and cyclones

3. Clinker Production

Clinker chute liners
Silo outlet liners
High-temperature ducts and fans

4. Finish Grinding (VRM)

Separator blades
Vertical mill rollers and tables (repair + refurbishment)
Fan casing liners

Why Cement Plants Choose D-Plate

Extends service life 3–10 times compared to carbon steel
Reduces downtime and maintenance frequency
Stable, crack-resistant overlay suitable for high-speed airflow
Customizable alloy formulas for abrasion, erosion, heat and particle impact
Supports D-Tech 3R onsite refurbishment for VRM and critical components

D-Plate helps cement plants increase reliability, reduce costs, and maintain higher throughput across their entire production line.

Documents:

4. D-Plate100 - Testing reports
5. KOVI Catalogue for powder specifications

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In a world where industries are constantly pushed to do more with less — less time, less waste, and less downtime — the real edge no longer comes from bigger machines, but from smarter, more sustainable materials.
D-Plate, the dual-component wear-resistant steel plate developed by BCC, represents not just an innovation in metallurgy, but a shift in how we think about industrial longevity, intelligence, and balance.

1. Predictive Maintenance Revolution

For decades, wear protection has been reactive: equipment wears down, production stops, parts are replaced, and losses are accepted as “the cost of doing business.”
D-Plate changes that paradigm.

Each D-Plate produced through Powder Overlay Process (POP) carries measurable performance data — from wear rates and alloy composition to environmental stress indicators. When integrated into digital monitoring systems, these data points create a real-time picture of surface health and predict when maintenance should occur before failures happen.

In industries like cement, mining, and power generation, where unplanned shutdowns cost thousands of dollars per minute, this insight is transformative. Maintenance becomes proactive, downtime becomes predictable, and operations shift from “repairing damage” to “preventing loss.”

D-Plate is not just a shield against wear — it is a sensor of resilience.

2. Sustainability Through Longevity

Every ton of steel saved is a ton of CO₂ not emitted. In this sense, sustainability is not only about recycling — it’s about lasting longer.
By extending the service life of industrial components three to five times compared to conventional wear plates, D-Plate helps reduce total material consumption, energy usage, and replacement frequency.

In line with ESG and CBAM standards, this means factories using D-Plate can report lower embodied carbon footprints and contribute directly to sustainable industrial operations.
A plant that runs longer between replacements does more than save money — it protects the planet.

As BCC’s philosophy suggests, the goal is not maximum hardness at any cost, but optimal balance between strength, flexibility, and adaptability — a harmony much like Vietnam’s iconic Phở, where ingredients work together to create a perfect whole.

3. Beyond Existing Applications

Today, D-Plate has become essential in heavy industries such as cement, steel, mining, and coal-fired power plants.
But the potential applications go further.

Renewable energy: Wind turbine bases, biomass processing, and waste-to-energy systems all face severe wear environments where D-Plate can deliver durability and carbon efficiency.
Logistics and port systems: Conveyor chutes, ship loaders, and bulk handling components demand long-life wear protection in high-salinity or abrasive conditions.
Agriculture and construction equipment: D-Plate’s customizable alloy layers can be adapted for tillage, earth-moving, and resource-handling machines where impact and abrasion coexist.

Even more intriguing is the future of localized manufacturing through the D-Plate Standard Workshop model.
By establishing small-scale production cells close to end-users, BCC enables decentralized, low-emission, and high-efficiency fabrication — making advanced wear protection as accessible and adaptable as a bowl of freshly cooked Phở, served right where it’s needed.

The Future of Industrial Balance

The future of industry is no longer about choosing between performance and sustainability, cost and quality, or global and local. It’s about integration — finding balance.

D-Plate embodies that balance: between innovation and tradition, between data and steel, between global technology and local craftsmanship.
It’s not just another wear plate — it’s a philosophy of industrial harmony, where longevity fuels sustainability, and intelligence fuels resilience.

The future is now. It’s built layer by layer, in every D-Plate.

https://docs.google.com/forms/d/1a3qccEFnFt-XtXb_icxf21GoAZKYa346zvF6eyhnOj4

Supported documents:

1. D-Plate Standard Workshop Introduction

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The BCM WP-Series is a fully automatic welding system designed and manufactured by BCC’s automation division – BCM.
It is specifically engineered for hardfacing and wear plate production, integrating advanced motion control, intelligent process management, and robust industrial components for maximum performance and reliability.

Engineered for Industrial Endurance

Developed from the proven BCM V-Series, the WP-Series has been optimized for continuous operation under demanding conditions — high temperature, heavy load, and long welding cycles.
Its architecture supports single or dual-torch configurations, making it ideal for high-productivity overlay welding applications such as D-Plate manufacturing.

Each system includes:

High-precision multi-axis welding carriage
Digital BCM HS-1000 Power Source co-developed with AOTAI
Integrated wire and powder feeding systems
Fume extraction unit for clean and safe operation
Wireless control interface and industrial-grade HMI

Smart Control, Simple Operation

The WP-Series combines digital control logic with an intuitive user interface to simplify setup and operation:

Multi-touch 7” industrial HMI with real-time process monitoring
Wireless handheld remote for mobility and ease of control
Automatic parameter storage – records welding data for each batch
Seamless integration with POP (Powder Overlay Process) for alloy customization

Operators can easily adjust:

Travel distance and oscillation range
Wire and powder feed rates
Voltage, current, and deposition parameters

These settings ensure consistent overlay thickness, metallurgical bonding, and uniform hardness across each D-Plate.

Key Technical Specifications

Reliability Built Into Every Component

The control panel is assembled using premium components from global suppliers, ensuring stable performance in harsh production environments.
Combined with a modular frame design, the WP-Series allows easy maintenance, quick part replacement, and minimal downtime.

Its black and yellow industrial finish represents BCM’s design identity — modern, durable, and engineered for longevity.

Integrated with D-Plate Manufacturing

The BCM WP-Series is the core automation platform used in D-Plate Standard Workshops worldwide.
It directly connects to BCC’s proprietary POP (Powder Overlay Process), enabling precise control over powder composition and deposition patterns.

Together, D-Plate and BCM WP-Series deliver a complete wear-protection ecosystem:

High-performance alloy overlays
Repeatable production quality
Scalable localized manufacturing

Precision. Flexibility. Productivity.

Whether integrated into a centralized production facility or deployed in a local D-Plate Workshop, the BCM WP-Series ensures that every wear plate is made with consistency, strength, and metallurgical accuracy.

Supported documents:

1. D-Plate Standard Workshop Introduction

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In today’s industrial landscape, sectors such as cement, steel, and mining face growing pressure to reduce emissions, save energy, and extend the lifespan of resources. “Sustainability” is no longer a slogan — it has become a condition for survival, not only for businesses but for the planet itself.

At BCC, the answer to this challenge lies in a clear philosophy:
Technology should not only make us stronger — it should help us live in harmony with nature.
D-Plate embodies this belief in every layer of steel it carries.

1. When Steel Longevity Becomes an Environmental Value

In most heavy industries, hundreds of tons of steel parts — liners, hoppers, ducts, and conveyors — are replaced each year due to wear and abrasion. These worn-out components quietly generate mountains of metal waste, hours of downtime, and massive energy losses.

D-Plate changes that equation.
With its dual-layer design — a ductile steel base and a hard overlay made with Powder Overlay Process (POP) technology — each D-Plate lasts 10 to 12 times longer than regular steel plates.
That means:

Fewer replacements → less metal waste
Lower production and transportation energy
Reduced CO₂ emissions over the equipment’s lifetime

In a 1-million-ton cement plant, replacing just 10% of wear parts with D-Plate can reduce carbon emissions by the equivalent of planting thousands of trees every year.
That’s not just a technical improvement — it’s a true environmental contribution.

2. POP Welding – Like Cooking Vietnam’s Perfect Phở Broth

If metallurgy were an art of cooking, then POP welding would be the art of crafting the perfect Phở broth.
In Vietnamese culture, every bowl of Phở — the national noodle soup — is defined by the balance between ingredients: clear yet flavorful broth, tender noodles, fragrant herbs, and a touch of spice. The secret lies in matching the broth to the dish — Phở bò (beef) has a completely different recipe from Phở gà (chicken), or from bún thang and hủ tiếu.

The same applies to industrial wear.
Each wear mechanism — abrasion, erosion, corrosion, impact, heat, cavitation — requires its own “recipe” of alloy composition and ratio.

BCC has developed dozens of “powder recipes” for D-Plate, blending elements such as Cr, Ni, Mo, Nb, Ti, and B to achieve the perfect balance of hardness, ductility, and heat resistance.
Each formula is like a unique broth — crafted for a specific industrial condition.

That’s why D-Plate is not just a product, but a customized solution, “cooked” precisely for the working environment of each customer.

3. Sustainability Begins with Understanding Materials

A product doesn’t last long just because it’s harder — it lasts because it’s more compatible with nature.
In BCC’s philosophy, sustainability doesn’t mean fighting against natural forces; it means understanding and working with them.

POP technology allows precise control of particle size, alloy distribution, and crystal orientation to create an intelligent surface — a “smart steel skin.”
It offers:

Superior wear resistance
Impact absorption
Thermal stress distribution
Easy recyclability

Each of these attributes contributes to a smaller carbon footprint — less repair welding, less material waste, and less electricity consumed over time.

4. Each D-Plate – A Seed of Environmental Happiness

At BCC, we define “environmental happiness” not as a quiet, untouched nature — but as a balanced relationship between production and regeneration.

When a cement plant runs more stably, when maintenance is reduced, and when the surrounding environment stays cleaner — that is happiness.
D-Plate helps make that possible.

Every D-Plate installed means:

Fewer breakdowns and safer working hours for technicians
Lower operating costs for manufacturers
Cleaner industrial ecosystems for local communities

Each plate becomes a seed of environmental happiness — extending the life of machines while reducing the strain on Earth’s limited resources.

5. From Green Technology to a Sustainable Culture

True sustainability starts not from machines, but from people and culture.
BCC’s vision is to build not only wear-resistant steel but also a culture of respect — for materials, for the environment, and for human craftsmanship.

Every engineer trained in a D-Plate Standard Workshop understands the connection between a single technical decision and its environmental consequence.
Each batch of alloy powder is weighed not only by grams — but by the awareness that “we are saving energy for the planet.”

Through the D-Plate Standard Workshop initiative, BCC brings this philosophy to life:
local production, local training, local sustainability — ensuring that the knowledge of wear protection grows together with the communities that use it.

6. Happiness – The Ultimate Measure of Technology

D-Plate represents a new direction for Vietnam’s industrial development — self-reliant, innovative, and responsible.
Responsible not only to customers but also to the environment, to society, and to future generations.

Because true development isn’t measured by how many tons of steel we produce,
but by how much trust, stability, and happiness we preserve for the future.

“Each D-Plate is not just a piece of steel — it’s BCC’s commitment to a greener, happier planet.”

https://docs.google.com/forms/d/1a3qccEFnFt-XtXb_icxf21GoAZKYa346zvF6eyhnOj4

Supported documents:

1. D-Plate Standard Workshop Introduction