Macro-cement compositions, method of producing macro-cement and engineered forms of macro-cement, and multi-stage homogenization process for preparing cement based materials

A method for producing cement-based materials using multi-stage homogenization comprising:

• producing a multi-component macro-cement by coating or loading micron-sized particles of cementitious materials with supplemental cementitious materials (SCM's) of submicron or nano-sized particles or a combination thereof;
• injecting the macro-cement into an intense moving energized water stream;
• producing a first mixture by homogenizing the water stream with the macro-cement in an intensive homogenizer with an energy density sufficient to overcome cohesiveness of the macro-cement to substantially complete dispersion and homogenization without separation of multi-component macro-cement and water;
• directing the first mixture into a second mixer with lower energy density than the intensive homogenizer;
• adding larger size particles into the second mixer;
• producing a second mixture by mixing the first mixture and the larger size particles in the second mixer to sufficiently match conditions of substantially complete homogenization of the second mixture without separation of multi-component macro-cement, water, and larger size particles;
• directing the second mixture into a third mixer with lower energy density than the second mixer;
• adding larger aggregates into the third mixer;
• producing a third mixture by mixing the second mixture and the larger aggregates in the third mixer to sufficiently match conditions of substantially complete homogenization of the third mixture without separation of multi-component macro-cement, water, larger size particles and larger aggregates.