Table of contents:
The ATEX Directive is one of the most important pillars ensuring safety in explosion-risk zones. Its name originates from the French phrase “ATmosphères EXplosibles” (explosive atmospheres). The primary mission of the ATEX Directive is to protect workers and the environment from the consequences of explosions involving flammable substances – ranging from gases and vapours to grain dust or wood dust.
From a legal perspective, two main directives form a coherent regulatory system. The first, ATEX 2014/34/EU, is aimed at manufacturers of equipment and protective systems intended for use in areas at risk of explosion. The second, ATEX 99/92/EC, focuses on employers and the methods of organising a safe working environment. These two directives complement each other closely, creating a comprehensive set of rules – from the design and production of machinery, through their certification, to their operation in real-world conditions.
The most critical concept at the heart of the ATEX Directive is the explosive atmosphere. This refers to a mixture of air and a flammable substance (gas, mist, vapour, or dust) that, at the right concentration and in contact with an ignition source, can trigger a violent reaction. Such incidents have the potential not only to destroy infrastructure or machinery but – most importantly – pose a serious threat to health or life.
Why is ATEX so vital in the context of safety? Above all, it harmonises standards across European Union countries. Previously, individual nations had their own regulations, which complicated both trade and the issue of protection itself. Manufacturers wishing to sell equipment in multiple countries had to comply with various rules – now, meeting ATEX requirements is sufficient. Meanwhile, employers have gained clear guidelines that help them organise work in a way that minimises the risk of explosion.
The ATEX Directive does not apply solely to large industrial facilities like refineries or petrochemical plants. Its scope is much broader, as it also considers places where flammable dusts (e.g., in bakeries, mills, or sugar warehouses) or flammable gases (e.g., in small workshops) are present to be potentially hazardous. Every entity where an explosive atmosphere might occur should comply with ATEX regulations.
The ATEX Directive is not a single document but two complementary legal acts: ATEX 2014/34/EU and ATEX 99/92/EC. Together, they form a cohesive system aimed at preventing explosions and protecting people and property in hazardous areas. Each act focuses on a different aspect:
ATEX 2014/34/EU – Directed at manufacturers of equipment and protective systems.
Defines how to design and manufacture products so they do not become ignition sources.
Indicates the need for testing and risk analysis.
Introduces the requirement for ATEX (Ex) labelling and issuing an EU Declaration of Conformity.
ATEX 99/92/EC – Focuses on employers and the organisation of a safe working environment:
Requires the classification of explosion hazard zones.
Demands the creation of an Explosion Protection Document (EPD).
Emphasises the need for regular employee training and equipment inspections.
This combination ensures that the regulations cover the entire lifecycle of a device: from its design, through certification and production, to its daily use in an industrial plant, warehouse, or workshop.
How broad is the scope of ATEX?
ATEX applies wherever explosive atmospheres exist or may occur. It is not limited to petrochemical facilities or mines, although these are naturally heavily included. It also encompasses the food industry (e.g., flour or sugar dust), painting and coating sectors (solvent vapours), the wood industry (wood dust), and even pharmaceuticals (chemicals with low ignition temperatures). Crucially, the ATEX Directive does not distinguish by company size. Even a small business may fall under its regulations if it handles substances that could create an explosive atmosphere.
The legal basis lies in the Treaties of the European Union, which grant the European Commission the authority to issue directives harmonising regulations across Member States. These directives must then be transposed into national law, meaning individual countries implement them through statutes or regulations with similar (or identical) content. This ensures that manufacturers and employers operating in the EU have clear, uniform rules, regardless of the Member State in which they operate.
From the perspective of manufacturers, meeting ATEX standards guarantees that their equipment can be sold throughout the EU. For employers, the 99/92/EC regulations serve as a roadmap for setting up workspaces and organising work to minimise explosion risks. Therefore, during inspections, a company must demonstrate not only the possession of properly labelled equipment but also comprehensive documentation (e.g., EPD, training records, and inspection logs).
ATEX regulations align with the concept of a systematic approach to safety. This means that manufacturers are responsible for designing equipment that does not become an ignition source, while employers are accountable for implementing proper procedures and maintaining equipment in good technical condition. This philosophy effectively reduces the number of incidents, thereby protecting people and the environment from the consequences of explosions.
Proper classification of explosion hazard zones is the foundation of effectively implementing ATEX principles. It determines in which areas an explosive atmosphere exists, how frequently it occurs, and what protective measures need to be applied.
Why is this important? The classification dictates the technical requirements for equipment (ATEX categories) and the safety procedures for a given location. Equipment with a higher safety category (e.g., Category 1G or 1D) is designed for zones where an explosive atmosphere is present almost continuously or for extended periods. In such areas, the risk of ignition is the greatest.
Zone 0: An explosive atmosphere is present continuously or for long periods (e.g., inside gas storage tanks).
Zone 1: There is a risk of an explosive atmosphere occurring during normal operating conditions (it may appear frequently but not continuously). An example could be the area around fuel tank filling chambers.
Zone 2: An explosive atmosphere occurs rarely and for short periods, e.g., during unexpected leaks of flammable substances.
Zone 20: Combustible dust is present as a cloud continuously or for long periods (e.g., inside grain silos).
Zone 21: Dust may form an explosive atmosphere under normal operating conditions (e.g., near equipment transferring dust).
Zone 22: Combustible dust occurs rarely and for short periods, e.g., during emergencies or minor leaks.
Key aspects:
Frequency and duration of the explosive atmosphere – this is the criterion that determines the choice of zone.
Type of flammable substances – gases, vapours, mists, or dusts require a similar approach but differ in designation (G for gas, D for dust).
Equipment suitability – Zones 0/20 require the highest level of protection (Category 1G/1D), while Zones 2/22 can use equipment with a lower category (e.g., 3G/3D).
Employer obligations (in accordance with ATEX 99/92/EC):
Conducting a risk assessment and determining whether and where explosive atmospheres may form.
Designating Ex zones and preparing appropriate zonal maps.
Including all zones and preventive measures in the Explosion Protection Document (EPD).
Carrying out regular inspections and updating the plan, especially when changes occur in the production process.
Correct classification of zones ensures that workers use equipment suited to the level of risk and that safety procedures are tailored to real conditions. Importantly, this classification must be continuously updated. Introducing a new substance with a lower ignition temperature or altering technological processes may necessitate redefining zones or upgrading equipment previously deemed suitable for use.
ATEX 2014/34/EU focuses on manufacturers of equipment intended for use in explosion hazard zones. Its primary objective is to ensure that products placed on the market do not become ignition sources, thereby posing no threat to workers or infrastructure.
Risk assessment and identification of ignition sources
Implementation of safeguards
Preparation of technical documentation
ATEX (Ex) labelling
EU Declaration of Conformity
Group I: Equipment intended for use in underground parts of mines (exposed to methane and dust).
Group II: Equipment for other sectors (chemical, food, pharmaceutical, painting industries, etc.).
Why is this so important?
Equipment used in explosion hazard zones must remain safe even in the event of a failure. For example, if a cable is worn or a flammable substance leaks, the equipment should still not generate sparks or excessive heat. This is why ATEX 2014/34/EU imposes rigorous tests and procedures that manufacturers must complete before their equipment can be placed on the market.
Product lifecycle:
Design and prototype: ATEX requirements are considered from the concept and design stage of the equipment.
Mass production: The facility must maintain consistent quality, often monitored by notified bodies as part of oversight.
Upgrades and repairs: Any changes introduced must be evaluated for safety.
Operation: The equipment must be used in the conditions and zones it was designed for. It is forbidden to “transfer” equipment rated 3G to Zone 0, as this risks an explosion and violates regulations.
Importers and distributors also have responsibilities. If they bring equipment from outside the EU, they must ensure that the products have undergone ATEX conformity assessment procedures and possess the appropriate documentation. This prevents unsafe and unverified equipment from entering the EU market.
ATEX markings on equipment play a crucial informational role. They allow users to easily determine the conditions under which a given device can operate without the risk of igniting an explosive atmosphere. Understanding the symbols and abbreviations is not just a formality but a practical safety tool.
“Ex” symbol
Equipment group (I or II)
Category (1, 2, 3) + atmosphere type information (G – gas, D – dust)
Type of protection (e.g., Ex d, Ex e, Ex i…)
Gas or dust explosion group (e.g., IIA, IIB, IIC)
Surface temperature (e.g., T1, T2, T3, T4, T5, T6)
Protection level (e.g., Gb, Db, Ga, Da)
II 1G Ex ia IIC T4 Ga
II – Equipment group (non-mining).
1G – Category (highest safety level for gases, Zone 0).
Ex ia – Type of protection (intrinsic safety).
IIC – Explosion group (gases such as hydrogen, acetylene).
T4 – Maximum surface temperature (135°C).
Ga – Highest protection level for gases (EPL).
How to read and apply this information in practice?
Direct equipment selection: When designing or operating a system in an Ex zone, you must ensure that the category and type of protection match your zone classification (e.g., Zone 1 – 2G equipment).
Maintenance and servicing: Technical staff, seeing a marking like T4, know that the equipment’s casing should not exceed 135°C. If measurements show higher values, it’s an alarm signal.
Health and safety inspections and audits: Inspectors verify whether the equipment markings align with the designated zones in the facility.
Employee training: Understanding markings is a key component of hazard awareness and incident prevention.
Certification is a process that officially confirms the compliance of equipment with the ATEX 2014/34/EU Directive. It provides users with assurance that the manufacturer has undergone a comprehensive risk assessment procedure and implemented appropriate explosion protection measures.
Risk assessment and design
Inspection and testing by a notified body
Production quality system
EU Declaration of Conformity
CE and Ex marking
Legal entry to the EU market: Without ATEX certification, equipment cannot be sold or used in explosion hazard zones within the EU.
Building trust: Certification enhances brand credibility and makes it easier to attract customers.
Minimising legal risk: In the event of an accident, the manufacturer can demonstrate that every effort was made to ensure the product’s safety.
Safety assurance: Certified equipment has undergone rigorous testing and been approved by a notified body.
Legal compliance: The buyer can confidently use the product in their installations without worrying about breaching ATEX regulations.
Easier inspections: Health and safety inspectors and regulatory authorities can quickly determine whether the equipment meets requirements. Simple verification of documentation and markings speeds up procedures.
Time-consuming: The certification process can be complex, especially for highly sophisticated equipment.
Costs: These include laboratory testing, fees for the notified body, and audits of quality systems.
Documentation: The manufacturer must maintain a consistent and up-to-date set of documents at every stage of the product’s lifecycle.
The benefits undoubtedly outweigh the challenges. Certification not only opens the door to the European Union market but also genuinely enhances safety levels in workplaces. Properly designed and tested equipment serves as a barrier protecting workers from the consequences of an explosion. As a result, both business owners and operators can be confident that they are using equipment that meets the highest explosion protection standards.
Explosion risk assessment
Classification of Ex zones
Explosion Protection Document (EPD)
The primary formal document in the facility:Personnel training
Maintenance and inspections
Safety culture
Why is this so important?
It happens that an employer has excellently designed ATEX-certified equipment but fails to conduct regular training or thorough inspections. As a result, even the best equipment can cause an accident if improperly operated or maintained. ATEX 99/92/EC highlights that safety in Ex zones is not a one-off check but a continuous process – involving analysis, implementing preventive measures, monitoring conditions, and training staff.
Benefits of implementing ATEX 99/92/EC:
Accident reduction: Well-defined procedures and trained staff lower the risk of ignition.
Limiting financial losses: Fewer breakdowns and downtime, reduced compensation and repair costs.
Positive reputation: A company that prioritises employee and environmental safety gains greater trust from clients and partners.
Legal compliance: No fear of legal or administrative penalties that come with ignoring regulations.
In effect, the ATEX 99/92/EC Directive is not just an obligation but a powerful tool for managing workplace safety. It protects against the severe consequences of explosions, giving employees confidence that their health and lives are being considered.
Explosion protection is not static – it continuously evolves in response to technological advancements and changes in industry. The ATEX Directive – while built on a solid legal foundation – in practice adapts with the introduction of new digital, material, and organisational solutions.
IoT devices in Ex zones: More and more machines and sensors are equipped with wireless communication modules, enabling remote monitoring of parameters (e.g., temperature, vibration). This allows maintenance teams to detect anomalies and respond faster, preventing ignition.
Remote control: In some facilities, employees enter Ex zones only when necessary, as installations are managed via secure panels or applications in a controlled environment.
Anti-static coatings: There are increasingly more solutions to reduce the accumulation of electrostatic charges. This lowers the risk of sparking, especially when working with dusts.
Lightweight and durable composites: Designers of Ex equipment are turning to materials that combine high mechanical resistance with low weight and non-flammable properties.
IECEx: An international certification system that complements ATEX. Manufacturers often seek recognition under both the European Union’s ATEX and the IECEx framework to expand their potential markets.
Collaboration between notified bodies: Many laboratories and research institutes enter agreements to streamline the conformity assessment process and avoid duplicating tests.
Virtual reality (VR): Employees can “enter” an explosion hazard zone in a digital environment. They practice responses to gas leaks or dust ignition without being exposed to real danger.
E-learning platforms: Online courses allow for regular knowledge updates and quick adaptation to regulatory changes.
Digitalisation of documents: The Explosion Protection Document (EPD) and other files are often maintained electronically. This simplifies updates and allows regulatory bodies to easily review the change history.
Internal audits: Companies are increasingly opting for voluntary audits to avoid unexpected issues during external inspections and to reduce the risk of accidents.
Cybersecurity in Ex Zones: Integration with industrial IoT systems brings the risk of hacker attacks. While ATEX primarily protects against explosions, the “cyber” aspect should not be underestimated — interference with device settings can affect its operation and safety.
New Flammable Substances: Industry continually introduces new chemical compounds that may have previously unknown ignition properties. Standards and testing methods will need to adapt to these emerging hazards.
These trends show that the ATEX area is dynamic. Companies aiming to maintain the highest level of safety must constantly monitor technological, legal, and organizational changes. This translates into real benefits: fewer accidents, lower operating costs, and increasing customer trust. By combining traditional explosion protection principles with new Industry 4.0 solutions, the ATEX system is becoming increasingly refined and more effective at protecting both people and the environment.
The ATEX Directive — understood as a coherent set of principles stemming from ATEX 2014/34/EU and ATEX 99/92/EC — enables comprehensive explosion risk management across various industries. On one hand, it provides manufacturers with clear guidelines regarding the design, certification, and marking of equipment. On the other hand, it imposes obligations on employers concerning zone classification, creation of explosion protection documents (EPDs), regular training, and monitoring of working conditions.
Benefits include:
Improved safety: Fewer accidents and explosion-related incidents, better protection of people and infrastructure.
Harmonized regulations: A single directive for the entire EU simplifies trade and cooperation, eliminating differences between national regulations.
Greater trust in manufacturers: ATEX certification confirms that the equipment has undergone rigorous testing and meets the highest standards.
Cost optimization: Preventing explosions is significantly cheaper than repairing the aftermath or paying compensation.
Professional image: Companies that comply with ATEX are perceived as responsible and innovative, which boosts their competitiveness in the market.
Compliance with ATEX guidelines is an investment in the long-term safety and development of the enterprise.
