System and method for coating a fire-resistant material on a substrate

A system for coating a cementitious fire-resistant substance onto a substrate, the system comprising:

• a substrate coater for depositing a layer of cementitious fire-resistant substance on the substrate in slurry form to initiate a penetrating process of the cementitious fire-resistant substance into the substrate, wherein the substrate and the substrate coater are supported for motion relative to each other;
• a veil coater for coating an amount of the cementitious fire-resistant substance in a slurry form onto a pliable carrier veil such that the cementitious fire-resistant substance is deposited in and on said pliable carrier veil to form a veil layer, wherein the veil coater delivers the veil layer uncured to the substrate such that the substrate and veil layer are coupled by the cementitious fire-resistant substance on the veil layer and on the substrate blending to form a continuous layer, wherein the substrate and the veil coater are supported for motion relative to each other;
• an oven for applying an initial amount of heat to the coupled substrate and veil layer for initiating a curing reaction in the cementitious fire-resistant substance;
• a transport means for transporting the coupled substrate and veil layer from the oven to remove the accelerating heat and allow the blended layer of cementitious fire-resistant substance to slow cure to promote a cementitious bond with the substrate surface;
• and
• a controller for providing a selected fire resistance to the substrate coupled with the veil layer by controlling the amount of said cementitious fire-resistant substance the veil coater deposits in and on said pliable carrier veil, controlling an amount of slurry form of cementitious fire-resistant substance deposited by the substrate coater on the substrate, controlling a rate at which the uncured veil layer is delivered by the veil coater to the substrate, controlling an intensity of the initial amount of heat applied by the oven, or controlling a transport rate of the transport means to control a period of time the initial amount of heat is applied to the coupled substrate and veil layer.