A device and a process for the continuous application of a refractory slurry to a surface incorporate a batch reactor (10) for the controlled mixing of the slurry, a product vessel (60) in communication with the batch reactor (10) to contain the mixed slurry, and a variable-rate spraying applicator or nozzle in communication with the product vessel and with an air supply. A controller (100) controls input to, output from, and the operation of, the batch mixer (10), and monitors batch production. The controller (100) monitors the amount of slurry contained in the product vessel (60). If the level of slurry in the product hopper is such that the product hopper cannot accommodate an additional batch of slurry, the controller interrupts batch production and resumes production when the product hopper can accept the contents of the batch reactor (10).

A waterborne facility on a body of water includes a primary spoolable pipe and a pump. The end of the primary spoolable pipe may be guided from the waterborne facility to a location proximate to a selected site. The pump may be used to discharge a flowable material through the primary spoolable pipe. The waterborne facility may include a ready-mix concrete preparation system. However, the waterborne facility may deliver any flowable material to a selected site, which may be a land surface, underground, on a water surface, or underwater. Illustrative flowable materials include seawater, grout, cement, and sediment/mud.

A system and method for applying a construction material is provided. The system may include a batching and mixing device configured to mix blast furnace slag material, geopolymer material, alkali-based powder, and sand to generate a non-Portland cement-based material, the non-Portland cement-based material including 4% to 45% geopolymer material by weight; greater than 0% to 40% blast furnace slag material by weight, 10% to 45% alkali by weight, 20% to 90% sand by weight, less than 1% sulfate by weight, and/or no more than 5% calcium oxide by weight; a conduit configured to transport the non-Portland cement-based material from the batching and mixing device; and a nozzle configured to receive the non-Portland cement-based material and combine the transported non-Portland cement-based material with liquid to generate a partially liquefied non-Portland cement-based material, wherein the nozzle is further configured to pneumatically apply the partially liquefied non-Portland cement-based material to a surface.

A device and a process for the continuous application of a refractory slurry to a surface incorporate a batch reactor (10) for the controlled mixing of the slurry, a product vessel (60) in communication with the batch reactor (10) to contain the mixed slurry, and a variable-rate spraying applicator or nozzle in communication with the product vessel and with an air supply. A controller (100) controls input to, output from, and the operation of, the batch mixer (10), and monitors batch production. The controller (100) monitors the amount of slurry contained in the product vessel (60). If the level of slurry in the product hopper is such that the product hopper cannot accommodate an additional batch of slurry, the controller interrupts batch production and resumes production when the product hopper can accept the contents of the batch reactor (10).

A system and method for applying a construction material is provided. The method may include mixing one or more of 4%-45% volcanic rock by weight, greater than 0%-40% latent hydraulic material by weight, 10%-45% alkaline component by weight, and 20%-90% aggregate by weight to produce a dry binding agent mixture, using a dry mixer; and combining the dry binding agent mixture with water at a nozzle to produce a sprayable concrete compound.

A system and method for applying a construction material is provided. The method may include mixing blast furnace slag material, geopolymer material, alkali-based powder, and sand at a batching and mixing device to generate a non-Portland cement-based material. The method may also include transporting the non-Portland cement-based material from the mixing device, through a conduit to a nozzle and combining the transported non-Portland cement-based material with liquid at the nozzle to generate a partially liquefied non-Portland cement-based material. The method may further include pneumatically applying the partially liquefied non-Portland cement-based material to a surface.

A method for coating a support with a lightweight insulating shotcrete, includes preparing the shotcrete by mixing, in predetermined proportions, at least a fibrous aggregate, a binder and water; pouring the prepared shotcrete in a tank; having at least one outlet; continuously moving the wet shotcrete in the tank until it reaches the or each outlet; sucking the wet shotcrete along a feeding pipe linking the outlet of the tank to a spraying gun, with a Venturi hose fed with pressurized air, included in the spraying gun; spraying the sucked shotcrete on the support with the spraying gun.

A system and method for applying a construction material is provided. The method may include mixing blast furnace slag material, geopolymer material, alkali-based powder, and sand at a batching and mixing device to generate a non-Portland cement-based material. The method may also include transporting the non-Portland cement-based material from the mixing device, through a conduit to a nozzle and combining the transported non-Portland cement-based material with liquid at the nozzle to generate a partially liquefied non-Portland cement-based material. The method may further include pneumatically applying the partially liquefied non-Portland cement-based material to a surface.

Manufactures, methods and apparatus are provided through which in some implementations a structural cellular lightweight concrete comprises a concrete mixture that is no more than 65% by volume of the manufacture of structural cellular lightweight concrete, the concrete mixture including concrete conforming to the requirements of ASTM C33; foam that has a density of at least 5 lbs/ft.sup.3, having high stability characteristics, and having a closed cell bubble structure; mix water being potable and free of contamination or deleterious materials; and Portland cement conforming to ASTM C150, the Portland cement being Type I, Type III or White Portland cement, and at least 35% air by volume of the manufacture of structural cellular lightweight concrete.

A system and method for applying a construction material is provided. The method may include mixing blast furnace slag material, geopolymer material, alkali-based powder, and sand at a batching and mixing device to generate a non-Portland cement-based material. The method may also include transporting the non-Portland cement-based material from the mixing device, through a conduit to a nozzle and combining the transported non-Portland cement-based material with liquid at the nozzle to generate a partially liquefied non-Portland cement-based material. The method may further include pneumatically applying the partially liquefied non-Portland cement-based material to a surface.