ATEX Zone Classification Hazardous Area Classification
Detailed ATEX hazardous area classification with scaled zone drawings. Zone 0, 1, 2 for gases and vapours; Zone 20, 21, 22 for combustible dusts. Equipment protection level specification and existing installation gap analysis.
ATEX Zone Classification Services
From initial assessment to professional zone drawings and equipment audits.
Zone Classification
Determination of zone type (0/1/2 or 20/21/22) and extent for every area where explosive atmospheres could form. Based on substance properties, quantities, containment, ventilation and process conditions.
Scaled Zone Drawings
Professional AutoCAD-quality zone drawings showing classified areas in plan and elevation with zone extents, equipment locations and ventilation boundaries. Suitable for electrical contractors and insurers.
Equipment Audit
Assessment of all electrical and mechanical equipment within classified zones against required ATEX protection levels. Identification of non-compliant installations requiring upgrade.
Equipment Schedules
Detailed schedules listing every piece of equipment in classified zones — current protection level, required protection level, compliance status and recommended action.
Earthing & Bonding Review
Assessment of earthing and bonding arrangements for static electricity dissipation — tanks, pipework, drums, IBCs, transfer hoses and personnel earthing in classified areas.
Zone Review & Update
Review of existing zone classification following process changes, substance changes, ventilation modifications or building alterations. Updated drawings and equipment schedules.
Risk Assessments for Your Sector
Every industry has different hazards. We tailor every assessment to your specific sector and operations.
Factories & Warehousing
Machinery, forklift, racking, noiseTransport & Logistics
Depot safety, loading bays, vehiclesConstruction
CDM, excavations, heights, demolitionSchools & Education
Classrooms, labs, playgrounds, tripsCare & Healthcare
Patient handling, clinical, infectionChemical
Process safety, COSHH, DSEARHospitality
Kitchens, fire, slips, public safetySMEs & Offices
DSE, fire, general workplaceCharities
Events, lone working, volunteersHow We Carry Out a Risk Assessment
Source Identification
We identify every potential source of explosive atmosphere release — process vessels, tanks, pipework flanges, valves, pumps, filling points, vents, drains and spillage points.
Release Assessment
For each source, we assess the grade of release (continuous, primary, secondary) based on frequency and duration, which determines the zone type.
Zone Extent
We calculate the extent of each zone using substance properties (flash point, vapour density, LEL), ventilation rates and containment effectiveness.
Zone Drawings
Professional scaled drawings produced showing all classified zones overlaid on your site plans. Plan and elevation views where required.
Equipment Gap Analysis
Every piece of equipment within classified zones is audited against the required protection level. Non-compliant items are listed with recommended actions.
ATEX Zone Classification FAQ
What is the difference between Zone 1 and Zone 2?
Zone 1: an explosive atmosphere is likely to occur during normal operation (e.g. near a process vent that regularly releases vapour). Zone 2: an explosive atmosphere is not likely during normal operation but could occur in abnormal conditions (e.g. a flanged joint that could leak if a gasket fails). Zone 1 requires higher-rated equipment than Zone 2.
Do I need zone drawings?
If your DSEAR assessment identifies explosive atmospheres, you need zone classification. Scaled zone drawings are best practice and essential for electrical contractors selecting and installing equipment. They also demonstrate compliance to HSE inspectors and insurers.
What equipment needs to be ATEX rated?
All electrical equipment within a classified zone — lighting, switches, sockets, motors, sensors, heaters, control panels, instrumentation, communication devices and portable equipment. Mechanical equipment that could generate sparks or hot surfaces may also need assessment.
What are Ex d, Ex e, Ex ia?
These are ATEX protection concepts: Ex d (flameproof enclosure), Ex e (increased safety), Ex ia (intrinsic safety — the highest level). The required concept depends on the zone type, gas group and temperature class of the substance involved.
Can you update existing zone drawings?
Yes. We review and update existing zone classification following process changes, new substances, ventilation modifications, building extensions or any other change that could affect explosive atmosphere formation.
How does ventilation affect zone classification?
Ventilation is critical. Effective ventilation reduces the extent and type of classified zones — potentially downgrading Zone 1 to Zone 2 or eliminating classification entirely. We assess natural and mechanical ventilation effectiveness as part of every zone classification.
How much does zone classification cost?
Based on facility size, number of release sources, complexity and whether existing drawings need updating or new classification is required from scratch. Contact us for a free discussion.
Need ATEX Zone Classification?
Get in touch for a free discussion about your facility and we'll provide a clear quote.