CE Certification for Concrete Repair and Protection Products: EN 1504 Guide

Products used for the repair and protection of damaged concrete in bridges, tunnels, parking structures, industrial facilities and buildings are placed on the market with CE marking under Regulation (EU) No 305/2011, commonly known as the Construction Products Regulation (CPR).

The relevant harmonised standards for these products are Parts 2 to 7 of the EN 1504 series. This guide explains the scope of each standard, the product categories covered, the essential characteristics declared in the Declaration of Performance (DoP), and the certification process under Assessment and Verification of Constancy of Performance (AVCP) System 2+.

At a Glance

Products covered by EN 1504-2 to EN 1504-7 are generally subject to AVCP System 2+ when intended for use in buildings and civil engineering works. The manufacturer determines the product type’s performance, establishes and implements Factory Production Control (FPC), and prepares the Declaration of Performance (DoP). A Notified Body assesses the FPC system and issues a Certificate of Conformity of Factory Production Control. Certain characteristics and intended uses, particularly those related to reaction to fire, may be subject to different assessment systems.

Overview of the EN 1504 Series

Standard	Product Category	Examples of Products
EN 1504-2	Surface protection systems for concrete	Hydrophobic impregnation (H), impregnation (I), coatings (C)
EN 1504-3	Structural and non-structural repair	Repair mortars and concretes: R4 and R3 (structural), R2 and R1 (non-structural)
EN 1504-4	Structural bonding	Epoxy-based adhesives and products for bonding plates and reinforcement elements
EN 1504-5	Concrete injection	Force-transmitting (F), ductile (D) and swelling-fitted (S) injection products
EN 1504-6	Anchoring of reinforcing steel bars	Anchoring mortars and resins for reinforcement bars
EN 1504-7	Reinforcement corrosion protection	Active coatings and barrier coatings

Other parts of the EN 1504 series provide supporting requirements and guidance. EN 1504-1 defines terminology, EN 1504-8 addresses quality control and conformity assessment, and EN 1504-9 establishes general principles and methods for the protection and repair of concrete structures.

The principles outlined in EN 1504-9, such as protection against ingress, structural strengthening and preservation or restoration of passivity, provide a useful framework for understanding the intended function of individual repair and protection products.

Can a Product Fall Under More Than One Part of EN 1504?

Yes. For example, a polymer-modified repair mortar may be declared both as an R3 repair mortar under EN 1504-3 and as a reinforcement corrosion protection product under EN 1504-7, provided that it meets the applicable requirements of both standards.

In such cases, each intended use and the corresponding standard must be identified separately in the Declaration of Performance. The Factory Production Control plan must also include appropriate controls to support all declared performances.

Essential Characteristics Declared in the Declaration of Performance (DoP)

The characteristics to be declared depend on the applicable part of EN 1504 and the intended use of the product. For a repair mortar covered by EN 1504-3, typical characteristics include:

Essential Characteristic	Description
Compressive strength	Minimum strength requirement according to the product class, with R4 having the highest requirement
Chloride ion content	Expressed as a percentage by mass
Adhesive bond strength	Tensile bond strength to the concrete substrate
Restrained shrinkage / expansion	Bond performance following restrained shrinkage or expansion
Resistance to carbonation	Particularly relevant to structural repair mortars
Elastic modulus	Applicable to structural repair mortars
Thermal compatibility	Freeze-thaw cycling, thunder-shower cycling or dry thermal cycling
Capillary absorption	Capillary water absorption coefficient
Reaction to fire	Product classification according to the Euroclass system
Dangerous substances	Requirements applicable at the place of intended use

For surface protection products covered by EN 1504-2, other characteristics are particularly relevant, including water vapour permeability, CO₂ permeability, capillary water absorption, chemical resistance and crack-bridging ability.

For hydrophobic impregnation products, penetration depth and drying rate are important performance characteristics, while adhesion strength is particularly relevant to protective coatings.

AVCP System 2+: Responsibilities of the Manufacturer and the Notified Body

Under Assessment and Verification of Constancy of Performance (AVCP) System 2+, the manufacturer and the Notified Body have clearly defined responsibilities.

Manufacturer’s Responsibilities:

Determine the performance of the product type using the test methods specified in the applicable part of EN 1504.
Establish, document and implement a Factory Production Control (FPC) system.
Carry out testing of samples taken during production in accordance with the prescribed testing plan.
Prepare the Declaration of Performance (DoP) and affix the CE marking.

Responsibilities of the Notified Body:

Perform the initial inspection of the manufacturing plant and its Factory Production Control system.
Conduct continuing surveillance, assessment and evaluation of Factory Production Control.
Issue, restrict, suspend or withdraw the Certificate of Conformity of Factory Production Control, as applicable.

Under System 2+, the Notified Body is not responsible for performing product-type testing. The document commonly referred to as a “CE Certificate” in the construction products sector is the Certificate of Conformity of Factory Production Control, issued following the successful completion of the certification process.

The applicable AVCP system may vary depending on the product’s intended use and specific essential characteristics. For example, products intended for applications subject to reaction-to-fire requirements may fall under different assessment systems.

The applicable system must be determined by consulting Annex ZA of the relevant harmonised standard. Sertifike’s designation as a Notified Body is limited to AVCP System 2+.

Key Factory Production Control Requirements for Concrete Repair and Protection Manufacturers

Raw material control: Acceptance criteria for cement, aggregates, polymers, resins and hardening agents.
Multi-component products: Individual traceability of components such as resins and hardeners, together with accurate declaration of mixing ratios on product labels.
Fresh product controls: Batch-specific checks covering consistency, density, workability and other relevant properties.
Hardened product testing: Verification of declared characteristics, including compressive strength and adhesive bond strength, at the frequencies specified in the testing plan.
Shelf life: Monitoring of storage conditions and shelf life, particularly for resin-based products.
Multiple declarations: Ensuring that the FPC plan covers all declared performances when a product falls within the scope of more than one part of EN 1504.

Documentation Required Before Applying for Certification

Before the initial inspection, manufacturers applying for Factory Production Control (FPC) certification for concrete repair and protection products should have the following information and records available:

A list of products to be included in the certification scope, specifying the applicable EN 1504 standard, product type or class (e.g., R4, H or F), and intended use.
Product-type determination test reports for each product.
Documented FPC procedures covering raw material acceptance, formulation management, batch identification, testing plans and frequencies, and the handling of non-conforming products.
A list of testing and measuring equipment, together with relevant calibration records.
Records demonstrating the individual traceability of components used in multi-component products.
Draft Declarations of Performance and examples of product packaging labels.

Example of a CE Marking Label

Illustrative CE marking label – Structural Repair Mortar

CE · 3228

Example Construction Chemicals Ltd., [address]

DoP No.: EX-RM-001

EN 1504-3:2005

CC mortar (cement-based) for structural repair, Class R4

Compressive strength: ≥ 45 MPa (R4) · Chloride ion content: ≤ 0.05% · Adhesive bond strength: ≥ 2.0 MPa · Resistance to carbonation: [declared performance] · Elastic modulus: ≥ 20 GPa · Capillary absorption: ≤ 0.5 kg·m⁻²·h⁻⁰·⁵ · Reaction to fire: [class]

For illustrative purposes only.

Common Mistakes to Avoid

Specifying a non-structural repair product classified as R1 or R2 for structural repair applications.
Declaring a product under multiple parts of EN 1504 while including controls for only one standard in the FPC plan.
Placing a product on the market for an application subject to fire regulations without declaring the required reaction-to-fire classification.
Providing inconsistent mixing ratios for multi-component products between the product label and the Declaration of Performance.
Confusing the repair principles defined in EN 1504-9 with the intended use declared in the DoP.

Frequently Asked Questions

What Is the Difference Between R3 and R4 Repair Mortars?

Both R3 and R4 are classifications for structural repair mortars under EN 1504-3. R4 requires higher compressive strength, adhesive bond strength and elastic modulus. It is generally preferred for repairing structural elements subject to higher loads.

What Is the Difference Between Hydrophobic Impregnation and Protective Coating?

Hydrophobic impregnation penetrates the pores of concrete, making the surface water-repellent without forming a continuous film. A protective coating, on the other hand, creates a continuous protective layer on the concrete surface.

Is a Notified Body Always Required for Products Covered by EN 1504?

The requirement depends on the applicable AVCP system, which is determined by the product’s intended use and relevant essential characteristics. For applications subject to System 2+, certification of Factory Production Control by a Notified Body is required. The applicable assessment system should be verified against Annex ZA of the relevant harmonised standard.

Can I Declare the Same Product Under Both EN 1504-3 and EN 1504-7?

Yes, provided the product satisfies the applicable requirements of both standards. Each intended use must be identified separately in the Declaration of Performance, and the Factory Production Control system must support both declarations.

Does the Notified Body Determine the Classification of My Repair Mortar?

No. The product classification is determined through testing carried out under the manufacturer’s responsibility and is declared in the DoP. The Notified Body assesses the Factory Production Control system to verify that the manufacturing process consistently maintains the declared performance.

Must the Shelf Life of a Repair Mortar Be Declared in the DoP?

Shelf life is not an essential characteristic required to be declared in the DoP. However, it is generally expected to be specified on the product packaging and in technical documentation, as it indicates the period during which the product retains its declared performance under appropriate storage conditions. Storage conditions and shelf-life controls are also assessed as part of Factory Production Control.

Fatih