Method of making a sprayable setting type compound

A method of making a setting type compound comprising:

• feeding a plaster compound and injecting an activator compound into a T-connector, wherein the T-connector has a first leg having a first inlet opening in communication with a first tube, the first tube comprising a second leg of the T-connector and a third leg of the T-connector, the second leg and the third leg being aligned, the second leg having a second inlet opening, the third leg having a discharge opening, the second inlet opening and the discharge opening being opposed;
• wherein feeding the plaster compound comprises pumping the plaster compound through the first leg into the first tube where the second leg meets the third leg at a specified first pressure and flowing the plaster compound at a specified first flowrate through the third leg of the first tube,
• injecting an activator compound at a specified second pressure and specified second flowrate through a second tube located within said second leg and extending into the third leg, the activator compound discharging from an exit at a downstream portion of the second tube located within and coaxial with the second leg of the first tube to contact the plaster compound;
• wherein the exit is upstream of the discharge opening of the first tube;
• wherein an annulus between the first tube and second tube at the exit has a first cross-sectional transverse area,
• wherein the second tube at the exit defines an inner second cross-sectional transverse area,
• wherein the first cross-sectional transverse area is equal to or greater than the second cross-sectional transverse area, and
• mixing the plaster compound with the activator compound in about a 1:1 to 10:1 volume ratio in a static mixer downstream of the exit to yield the setting type compound;
• wherein a ratio of the inner cross-sectional transverse area of the second tube to cross-sectional transverse area of an annulus between the first tube and the second tube is 0.25:1 to 1:1;
• wherein the specified first rate of flow and the specified second rate of flow are each in a range of 0.5-4 gpm,
• wherein the viscosity of the plaster compound is between 2,500 and 28,000 cps,
• wherein the viscosity of the activator compound is between 2,500 and 28,000 cps,
• wherein the viscosity of the activator compound, and the viscosity of the plaster compound and the viscosity of the setting type compound are equal;
• wherein the viscosity of the setting type compound is between 2,500 and 28,000 cps,
• wherein each of the specified first pressure and the specified second pressure is in a range from 1000 to 3500 psi.