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

1. 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.

2. The method of claim 1 , wherein the first mixture comprises a cement paste and the homogenizing of the cement paste with plastic viscosity μ Macro-Cement takes place with shear rate γ Macro-Cement providing shear stress τ Macro-cement in the cement paste in the range from dynamic yield stress τ o Macro-cement corresponding to minimum shear stress to maintain paste flow to ultimate dynamic stress τ d Macro-cement corresponding to fully destroyed structure of the cement paste, wherein the ultimate dynamic stress τ d is approximately ten times the dynamic yield stress τ o Macrocement so that τ 0 Macrocement <τ<10 τ o Macrocement , wherein the second mixture comprises a mortar paste and the homogenizing of the mortar paste with plastic viscosity μ mortar takes place with shear rate γ mortar providing shear stress τ mortar in the mortar paste in the range from dynamic yield stress τ 0 mortar corresponding to minimum shear stress to maintain paste flow to ultimate dynamic stress τ d mortar corresponding to fully destroyed structure of the mortar paste, wherein the ultimate dynamic stress τ d mortar is approximately ten times the dynamic yield stress τ 0 mortar so that τ 0 mortar <τ mortar <10·τ 0 mortar , wherein the third mixture comprises a concrete paste and the homogenizing of the concrete paste with plastic viscosity Ξ concrete takes place with shear rate γ concrete providing shear stress T concrete in the concrete paste in the range from dynamic yield stress τ 0 concrete corresponding to minimum shear stress to maintain paste flow to ultimate dynamic stress τ d concrete corresponding to fully destroyed structure of the concrete paste, wherein the ultimate dynamic stress τ d concrete is approximately ten times the dynamic yield stress τ 0 concrete so that τ 0 concrete <τ concrete <10·τ 0 concrete .

3. The method of claim 1 , wherein the intense moving energized water stream is provided with input energy by any of high-pressure nozzles, rotor-stator mixers, Venturi system or ultrasonic processors, the input energy being transformed into frictions, turbulences, micro-turbulences, waves, microwaves and cavitation promoting uniform and substantially complete macro-cement homogenization, or wherein the intensive homogenizer is a concrete mixer.