How to Minimize Concrete Popouts
Concrete is what happens when you mix cement powder, sand, stone and water. The sand and stone support most of the weight in a concrete structure and they are usually called "small and large aggregates." A "popout" is what happens when a stone, a large aggregate, near the surface of the concrete pops out and leaves a conical hole in the surface of hardened concrete. Popouts do not weaken concrete but they are ugly. Popouts are both preventable and fixable. Does this Spark an idea?
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Instructions
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Use "beneficiated aggregates" in your concrete mix. These are aggregates that have been treated to remove lighter stones. These aggregates cost more but will prevent popouts.
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Tamper concrete surfaces before screeding with a "jitterbug." "Screeding" pulls a board or other straight edge over concrete surfaces to smooth and compact the surface. A jitterbug is used to literally pound a concrete surface with a piece of metal shaped like a board. Pounding or tamping will push stones down into the concrete.
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Wet the concrete during curing with a fog nozzle and a hose to discourage popouts.
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Fix popouts by chipping any remaining aggregate from the hole with a hammer and chisel, cleaning out the hole with water then filling the hole with mortar. Note that It will be difficult to match the color of the new mortar and the cured concrete.
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References
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