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1) You didn't miscalculate; you just took 80, while 85 would create a full-fledged Titan.
2) Besides, it also has resistance. These were just thoughts.
3) In a battle against Chaos, you can't close ranks because half of Chaos's attacking spells are area-of-effect.
Judging by everything, Order will still lose. Chaos has a high turn priority; it can wipe out a significant part of the army at the beginning, and then Chaos takes over.