Home > Knowledge Hub > Blog

Safety in potentially explosive environments isn’t optional – it’s essential. Whether you’re responsible for lone worker safety, or operational compliance, understanding ATEX is key to reducing risk and safeguarding lives.

In this blog, we’ll answer some of the most frequently asked questions about ATEX regulations, equipment standards, and how the right lone worker devices can play a vital role in protecting staff operating in hazardous zones. From legal obligations to practical safety solutions, we’ll guide you through what you need to know to maintain a compliant and secure workplace.

What are ATEX Zones?

ATEX zones are used to classify areas where explosive atmospheres may occur, helping employers and duty holders choose the right equipment and implement appropriate safety measures. These zones are defined by the likelihood and duration of the presence of flammable gases, vapours, mists, or dust.

This classification system is a key part of the Dangerous Substances and Explosive Atmospheres Regulations (DSEAR) 2002, which require UK employers to assess and control risks in potentially explosive atmospheres.

Zone classifications for gases, vapours and mists:

Zone 0
An explosive atmosphere is present continuously, for long periods, or frequently. Example: Inside tanks or containers storing petrol or solvents.

Zone 1
An explosive atmosphere is likely to occur occasionally during normal operation. Example: Areas around pipework joints or filling points where vapours may be released.

Zone 2
An explosive atmosphere is not likely to occur in normal operation, and if it does, it will only persist for a short time. Example: Spaces near ventilation systems or equipment prone to minor leaks.

Zone classifications for combustible dusts:

Zone 20
A dust cloud capable of forming an explosive atmosphere is present continuously or for long periods. Example: Inside industrial mixers or silos for fine powders such as flour or sugar.

Zone 21
An explosive dust atmosphere is likely to occur occasionally during normal operation. Example: Around machinery where dust is released during processing.

Zone 22
A dust atmosphere is not likely to occur, and if it does, it will only exist briefly. Example: Areas where dust may build up and become airborne during cleaning or maintenance.

Why is ATEX zone classification important?

Correct zoning is essential to:

• Select the appropriate ATEX-certified equipment, including lone worker and man-down devices that won’t act as ignition sources.
• Implement effective risk control measures as required by DSEAR.
• Protect your employees, premises, and operational continuity.

ATEX zones form the foundation for a compliant and safe working environment in high-risk industries such as petrochemical, pharmaceutical, food processing, and manufacturing.

Why is ATEX-Certified Equipment Important?

ATEX-certified equipment plays a vital role in protecting people and operations in potentially explosive atmospheres, also known as Ex areas. In the UK, ensuring that equipment is ATEX-compliant also helps businesses meet their obligations under the Dangerous Substances and Explosive Atmospheres Regulations (DSEAR).

Here’s why it matters:

• Prevents Explosions
  ATEX-rated equipment is specifically engineered to avoid becoming an ignition source. It does not emit sparks, heat, or electrical faults that could trigger a fire or explosion.
• Protects Lone Workers and Staff
  In hazardous areas, personal safety alarms and man-down devices allow lone workers to raise the alarm instantly if something goes wrong—enabling fast, effective emergency response.
• Meets UK Legal Requirements
  Use of compliant equipment helps satisfy DSEAR regulations and avoid penalties or legal liability in the event of an incident.
• Minimises Downtime
  By preventing potentially catastrophic incidents, ATEX equipment helps reduce damage to assets and costly interruptions to operations.
• Performs Under Pressure
  Certified devices are built to function reliably in extreme environments, including high temperatures, heavy dust, and corrosive atmospheres.

Investing in ATEX-certified equipment is not just a compliance measure—it’s a proactive step to protect lives, ensure continuity, and maintain a safe workplace.

Which UK Industries Need ATEX Equipment?

ATEX regulations apply to any UK industry where flammable gases, vapours, mists, or dusts may be present. This includes a wide range of sectors where hazardous atmospheres are part of normal operations.

Key industries include:

• Chemical and Petrochemical
  Flammable substances such as solvents and hydrocarbons create explosion risks during manufacturing and processing. Certified lone worker systems support emergency response in high-risk zones.
• Oil and Gas
  Onshore and offshore sites frequently handle methane, propane, and other volatile compounds. ATEX-compliant safety devices protect staff during drilling, refining, and storage.
• Mining
  Underground environments are prone to explosive gases and combustible dust. Equipment must meet the highest safety category standards to protect miners and ensure operational safety.
• Food and Agriculture
  Fine organic dust (e.g., flour, grain, sugar) can form explosive clouds in silos and mills. ATEX-compliant personal alarms are a key part of risk mitigation strategies.
• Wood and Metalworking
  Dust from cutting, sanding, or grinding materials can ignite under the right conditions. Industries working with aluminium, magnesium, or fine wood dusts must use certified equipment to reduce the risk of fire or explosion.

No matter the sector, ATEX-certified devices are essential for safeguarding personnel and fulfilling employers’ duties under DSEAR and Health & Safety at Work legislation.

How is ATEX Equipment Certified in the UK?

ATEX certification is a rigorous process that confirms equipment is safe to use in explosive environments. In the UK, this is regulated under domestic legislation that mirrors the ATEX Product Directive (2014/34/EU), with conformity assessed via the UKCA marking system.

Step 1: Classification

First, the manufacturer determines:

• The ATEX zone where the equipment will be used
• The category of protection required (1, 2, or 3)
• Whether the product is electrical or non-electrical

Step 2: Certification Routes

Depending on the category and type of equipment, different certification procedures apply:

Category 3 Equipment
Suitable for low-risk zones (e.g., Zone 2 or 22). Manufacturers can self-declare compliance through internal production control, following UK regulations.

• Category 2 Equipment (Electrical)
  Requires UK-approved body assessment. The product must be tested, and the manufacturing process audited by the body.
• Category 2 Equipment (Non-Electrical)
  The manufacturer must submit technical documentation to an approved body but can carry out internal production control independently.
• Category 1 Equipment (All Types)
  Used in the highest-risk zones (Zone 0 or 20), this equipment must undergo full type examination and production oversight by an approved body.

Step 3: Technical Documentation

Manufacturers must compile detailed technical documentation proving compliance with relevant UK regulations. This must be retained for at least 10 years.

Step 4: Certification and Marking

After successful assessment, the product receives:

• A type examination certificate
• Authorisation to display the UKCA mark (or CE mark in Northern Ireland if applicable)
• A formal declaration of conformity

ATEX certification ensures that the equipment you rely on—such as gas detectors, personal alarms, or communication tools—won’t become an ignition source in explosive atmospheres. It’s a cornerstone of both compliance and safety in high-risk industries across the UK.

How Do I Know if a Device Is ATEX-Certified?

ATEX-certified equipment is marked with a distinctive hexagonal “Ex” logo, indicating that it has passed stringent safety testing for use in explosive atmospheres.

Key identifiers of genuine ATEX certification:

• The “Ex” Symbol
  Signifies that the equipment has been designed and tested to prevent ignition in hazardous areas.
• ATEX Category and Zone Markings
  The label will include a code such as “II 1G” or “II 2D,” which tells you what type of environment the device is certified for (e.g., gases or dust, and which zone).
• Manufacturer’s Information and Approval Body Code
  Indicates which UK-approved (or EU-notified) body carried out the conformity assessment.
• UKCA or CE Mark
  The UKCA mark confirms conformity for sale in Great Britain, while CE is required for Northern Ireland or EU markets.

These markings are not just legal requirements—they are also a clear indication that the device has been manufactured to operate safely in high-risk environments, including use by lone workers, emergency responders, and plant operators.

How Do ATEX Devices Prevent Explosions?

ATEX-certified devices are specifically engineered to prevent ignition in hazardous environments. Their design ensures that they do not become a source of sparks, heat, or electrical faults that could ignite explosive atmospheres.

Key safety features include:

• Elimination of Ignition Sources
  ATEX equipment avoids sparking, arcing, and excessive heat, all of which could cause explosions.
• Robust Enclosures
  Devices are constructed with sealed housings that contain internal faults and prevent the release of ignition energy.
• Electrostatic Protection
  Use of conductive materials and proper grounding reduces the build-up of static electricity.
• Strict Certification Testing
  Every ATEX-certified product undergoes comprehensive testing by a UK-approved (or EU-notified) body, ensuring it performs safely under real-world conditions.

These measures help protect not only lone workers and operators, but also critical equipment and the wider operational infrastructure in explosive risk zones.

What Are the Main Types of ATEX Protection?

There are several internationally recognised types of protection that determine how a device can safely operate in a potentially explosive atmosphere. These are defined by standards such as IEC/EN 60079, and are applied depending on the nature of the hazard—gas, vapour, mist, or dust.

1. Increased Safety (“e”)
Electrical components are reinforced to prevent arcs, sparks, or hotspots. Common in terminal boxes and lighting.

2. Flameproof Enclosure (“d”)
The enclosure contains any internal explosion and prevents it from igniting the surrounding atmosphere. Widely used in motors and switchgear.

3. Intrinsic Safety (“i”)
Limits energy within the circuit so that even under fault conditions, it cannot cause ignition. Ideal for sensors, portable devices, and control systems.

4. Encapsulation (“m”)
Sensitive components are embedded in resin or similar materials to isolate potential ignition sources.

5. Pressurised Enclosure (“p”)
Keeps the enclosure under pressure using clean air or inert gas (like nitrogen), preventing entry of hazardous gases or dust.

6. Oil Immersion (“o”)
Components operate in an oil-filled compartment that prevents sparks from reaching flammable atmospheres.

7. Non-Sparking Design (“n”)
Used in lower-risk zones (e.g., Zone 2), this protection limits the risk through careful design to avoid ignition-capable energy.

8. Dust-Tight Enclosure (“t”)
Prevents dust ingress and eliminates ignition risk in dusty environments. Crucial for food, agricultural, and wood processing sectors.

Understanding these protection types helps ensure that the right device is selected for the right zone—whether for Zone 1 (gases), Zone 21 (dusts), or Zone 0/20 (continuous risk).

Which ATEX Zones Is the SafeTouchEx Emergency Smartphone Suitable For?

The SafeTouchEx smartphone from Almas Industries is certified for use in Zones 1/21 and 2/22. This means it can be safely used in environments where there is a risk of explosive atmospheres due to the presence of flammable gases, vapours, or combustible dust.

It is ideally suited for:

• Petrochemical plants
• Food and agricultural processing
• Paint or chemical manufacturing
• Gas storage and distribution sites

With built-in lone worker protection, man-down detection, and emergency alerting, the SafeTouchEx ensures that workers stay connected and protected in high-risk environments.

Which Regulations Apply in the UK and Who Is Responsible for Compliance?

Unlike Europe, where explosion protection is governed by VEXAT, in the United Kingdom, the relevant legal framework is the:

Dangerous Substances and Explosive Atmospheres Regulations (DSEAR) 2002
These regulations implement key safety requirements for managing explosive atmospheres in UK workplaces. They are enforced by the Health and Safety Executive (HSE).

Employer Responsibilities Under DSEAR:

• Identify and classify hazardous zones (e.g., Zone 0, 1, 2 for gases; Zone 20, 21, 22 for dust).
• Conduct and document risk assessments.
• Implement control and mitigation measures—both technical and organisational.
• Use only ATEX/UKCA-compliant equipment appropriate for the zone classification.
• Provide regular training for staff who work in or near hazardous areas.
• Create and maintain an Explosion Protection Document, which outlines zoning, assessments, and safety procedures.

Who is legally responsible?

The employer or duty holder is legally responsible for ensuring DSEAR compliance. They must:

• Ensure safe working conditions.
• Select and maintain certified equipment.
• Train and inform staff on explosion risks.
• Review and update safety documentation as needed.

Non-compliance can lead to enforcement action by the HSE, including fines, prosecution, or shutdown of operations.