Injection products and systems

Injection products and systems are used for repairing concrete structures. A distinction is made between different repair objectives.

  • The filling objective 'Closing (crack width control by filling)' includes inhibiting or preventing ingress of corrosion-inducing substances (that attack concrete and steel) into the concrete structure through cracks.
  • The filling objective 'Sealing' includes eliminating crack- and void-related leaks and restoring the impermeability of a concrete structure by filling with injection products.
  • The filling objective 'force transmitting bond' aims at producing a compression-, shear- and tension-resistant bond between the crack or concrete flanks. The strength of these bonds depends on the type of repair product and the repair procedure used.
  • The filling objective 'ductile filling with limited ductility' aims at producing a bond between the crack or concrete flanks that is ductile to a limited extent and has filler-specific strength properties.

Depending on the filling objective and the type of injection, the following injection products and systems are differentiated:

  • Force transmitting filling (F) of cracks and voids is used to close (crack width control by filling), seal and bond concrete structures under static and dynamic loading in a force transmitting way.

    Injection products for force transmitting filling (F) are able to bond the crack flanks and transmit tensile, compressive and shear forces depending on the strength properties of the injection product. Suitable materials include epoxy resins (EP) as well as modified polyurethanes (mod. PUR), provided that they have a sufficient force transmitting performance. Furthermore, injection products formulated with hydraulic binders are used, e.g. cement paste, cement suspension.
  • Ductile filling (D) (with limited ductility) of cracks and voids is used to close (crack width control by filling), seal and bond (with limited ductility) concrete structures under static and dynamic loading.

    Injection products for ductile filling (D) are suitable for accommodating subsequent movements to a limited extent. Suitable materials include polyurethanes (PUR) as well as modified epoxy resins (mod. EP), provided that they have sufficient ductility. In the case of water flowing through the crack, fast-foaming polyurethane (SPUR) with sufficiently short reaction times and sufficient volume increases may be applied for sealing, where appropriate, before the actual injection is made.
  • Swelling fitted filling (S) of cracks and voids is used to seal concrete structures. Injection products for swelling fitted filling of cracks (S) adsorb and release water repeatedly (swell/dry). They are therefore only fit for use in permanently damp environments. Suitable materials include acrylic gels consisting of a reactive acrylic binder, catalyst, initiator and water and possibly polymeric fillers.

    Injection products for force transmitting filling (F) are applied by injection or grouting. Injection products for ductile filling (D) and for swelling fitted filling (S) are applied exclusively by injection. The injection product is injected using an injection device under controlled pressure via packers with insulation. In the case of injection products made of polyurethane (PUR), the insulation does not necessarily have to be used. A distinction is made between single-component injections and multi-component injections. In the case of single-component injections, the ready-mixed injection product is pressure-transported from the injection device to the packer. With multi-component injections, the individual components are transported separately under pressure from the injection device to the mixing head, mixed and conveyed on to the packer.

    When grouting injection products for force transmitting filling (F), the injection product is grouted without pressure using gravity or capillary suction on cleaned, prepared cracks ensuring a constantly filled filler reservoir. The required filling depth is determined and checked in advance.

Regulatory framework

DIBt prepares evaluations of the fitness for use of injection products in the area of transport infrastructure construction. The evaluations provide independent validation of additional information that cannot be stated in the declaration of performance.

It would also be possible to issue an ETA instead of an evaluation, however, there are no European Assessment Documents (EADs) for injection products as yet.

  • Injection products F and D:
    In accordance with the ZTV-ING and ZTV-W LB 219 (see 'Technical rules' below), the evaluations serve as 'verifiable confirmation' (prüffähige Bescheinigung) and are recognised as equivalent to project-specific verifications when they fully correspond to the construction specifications. The Notes on ZTV-ING (Hinweise zu den ZTV-ING) - Part 3 - Section 5 and the BAWRecommendation 'Repair Products – Notes for the expert designer on works-related product characteristics and test methods' (BAWEmpfehlung "Instandsetzungsprodukte – Hinweise für den Sachkundigen Planer zu bauwerksbezogenen Produktmerkmalen und Prüfverfahren") are to be observed to support the construction specifications and the execution of construction work.
  • Injection products S:
    Since DIN V 18028 does not cover acrylic gels, it is recommended to have the performance assessed and document it in a technical documentation with the involvement of a body qualified following Art. 30 of the Construction Products Regulation (Technical Assessment Body).

Technical rules

Injection products F and D:

ZTV-ING – Part 3 – Section 5
Federal Ministry of Transport and Digital Infrastructure, Department of Federal Highways (ed.):
Zusätzliche Technische Vertragsbedingungen und Richtlinien für Ingenieurbauten – Teil 3 Massivbau – Abschnitt 5 Füllen von Rissen und Hohlräumen in Betonbauteilen, October 2017.

Notes on ZTV-ING - Part 3 - Section 5
Federal Ministry of Transport and Digital Infrastructure, Department of Federal Highways (ed.):
Hinweise zu den ZTV-ING – Teil 3 Massivbau – Abschnitt 5 Füllen von Rissen und Hohlräumen in Betonbauteilen, April 2019.

ZTV-W LB 219
Federal Ministry of Transport and Digital Infrastructure, Department of Waterways, Shipping (ed.):
Zusätzliche Technische Vertragsbedingungen – Wasserbau – für die Instandsetzung der Betonbauteile von Wasserbauwerken (Leistungsbereich 219), June 2017

BAWRecommendation 'Repair products'
Federal Waterways Engineering and Research Institute (BAW) (ed.):
BAWEmpfehlung "Instandsetzungsprodukte – Hinweise für den Sachkundigen Planer zu bauwerksbezogenen Produktmerkmalen und Prüfverfahren", May 2019

Instandhaltung von Betonbauwerken (TR Instandhaltung): Teil 1 – Anwendungsbereich und Planung der Instandhaltung (86 pages)

Stand: Mai 2020

Instandhaltung von Betonbauwerken (TR Instandhaltung): Teil 2 – Merkmale von Produkten oder Systemen für die Instandsetzung und Regelungen für deren Verwendung (72 pages)

Stand: Mai 2020

Application forms

European Technical Assessment (ETA)

To start the ETA procedure, please submit the form below. We will then check if the prerequisites for issuing an ETA are met, i.e., in particular, if the product is not fully covered by an existing harmonised standard. If the prerequisites are met, we will check whether a European Assessment Document (EAD) covering the requested assessment scope already exists or still needs to be developed. If an EAD needs to be developed or amended, a complete technical file needs to be established before the procedure can begin.

Form for requesting a European Technical Assessment (ETA) (2 pages)

Last updated: 16 June 2022

Voluntary evaluations of fitness for use

Where the relevant harmonised standard is incomplete, economic actors can provide product performance information on a voluntary basis. DIBt offers independent validation and confirmation of such additional performance information in the form of a voluntary evaluation of fitness for use.

Auftrag zur Erstellung eines Gutachtens (4 pages)

über die Einhaltung bauaufsichtlicher Anforderungen an bauliche Anlagen bei Einbau des bezeichneten Bauprodukts

  • DIBt evaluation
  • The evaluations listed below are published with the kind consent of the evaluation holder. Evaluations which have not been released for publication are not made available by DIBt.
    Subject Prepared for Number Issued on
    Rissfüllstoff D(P) "PUR-O-CRACK"

    TPH Bausysteme GmbH

    Nordportbogen 8

    22848 Norderstedt

    G-003-18-0001 03.11.2020
    Rissfüllstoff F(P) "HYDROPOX EP1"

    TPH Bausysteme GmbH

    Nordportbogen 8

    22848 Norderstedt

    G-003-18-0010 05.11.2020
    Rissfüllstoff (S) "RUBBERTITE / POLINIT"

    TPH Bausysteme GmbH

    Nordportbogen 8

    22848 Norderstedt

    G-003-18-0011 27.02.2019
    Rissfüllstoff (S) "DRYflex 2 - DRYflex plus"

    Drytech Abdichtungstechnik GmbH

    Im Altenschemel 39a

    67435 Neustadt

    G-003-20-0002 24.03.2020

Dr Wilhelm Hintzen
Head of Section – Concrete Technology

Phone +49 30 78730-328
Email whi(at)dibt(.)de

Legal reference documents