Working Safely in ATEX Zones: What Do You Need?

Working in ATEX zones requires more than just “explosion-proof” equipment. It involves controlling ignition sources, correctly classifying zones, selecting appropriate personal protective equipment (PPE), and ensuring proper behavior, maintenance, and supervision. In this article, we clearly explain what ATEX zones are, what PPE you need in practice, which standards and markings are relevant, and which pitfalls you absolutely want to avoid. This will help you make the transition from regulations to practical safety on the job site.

It’s important to be clear from the start: ATEX in the workplace revolves around (1) ATEX 153 (1999/92/EC) for safe working practices, (2) ATEX 114 (2014/34/EU) for Ex equipment, (3) the Dutch implementation in the Working Conditions Act / Working Conditions Decree, and (4) PPE requirements from the PPE Regulation (EU) 2016/425. Below, we provide links to the official legal texts and regulatory authorities so that your decisions are demonstrably well-founded.

What are ATEX zones, and why is explosion safety important?

ATEX is a collective term for European regulations concerning explosive atmospheres. In practice, you’ll encounter two categories:

• ATEX 153 (formerly ATEX 137, Directive 1999/92/EC): focuses on safe working practices. This includes risk analysis, zoning, the Explosion Safety Document (EVD), procedures, training, and the selection of safe work equipment and PPE. 

• ATEX 114 (Directive 2014/34/EU): focuses on the placing on the market of equipment and protective systems intended for use in potentially explosive atmospheres. You can recognize this by the familiar “Ex” marking on the equipment. 

Important to note: ATEX 114 primarily applies to equipment. PPE falls under the PPE Regulation (EU) 2016/425 (with CE marking and product standards). PPE must, however, fit within the ATEX safety concept and must not introduce any additional ignition risks, such as through electrostatic charge or sparking.

Dutch obligations for employers (RI&E, measures, instruction, supervision) are derived from occupational safety and health legislation. 

What makes an environment explosive?

An explosion can occur when three elements come together: a flammable substance (gas, vapor, mist, or dust), oxygen, and an ignition source. In ATEX environments, there is a real risk that a flammable atmosphere is present—sometimes continuously and sometimes only during malfunctions or incidents. Ignition sources are more commonplace than one might think: static electricity, mechanical sparks, hot surfaces, electrical equipment, open flames, as well as unsuitable clothing materials or improperly selected tools.

Zone Classification: Gas and Dust

The zone classification determines how likely it is that an explosive atmosphere will occur. A distinction is made between gas and dust:

• Gases and vapors: Zone 0 (continuous or prolonged), Zone 1 (frequent), Zone 2 (occasional and short-term).

• Dust: Zone 20 (continuous or prolonged), Zone 21 (regular), Zone 22 (occasional and short-term).

This classification is not just a theoretical exercise. It guides the selection of equipment, work methods, and the PPE you use. In a dust zone, for example, visible dust buildup alone may mean you need to critically review your housekeeping practices and choice of clothing to mitigate electrostatic risks.

The Role of PPE in ATEX Zones

PPE is always the last line of defense in the occupational health and safety strategy within ATEX zones. First, you eliminate or reduce the explosion risk through process measures, ventilation, inerting, leak prevention, source control, zoning, and Ex-rated equipment. However, PPE remains essential to protect workers against residual risks, incidents, and secondary hazards such as fire, heat, chemicals, flying debris, noise, and hazardous substances.

An additional consideration in ATEX: PPE must not become a new ignition source. This means that antistatic properties, material selection, compatibility, and proper use are at least as important as the protection class itself.

Essential PPE for ATEX Zones

Safety helmet and face protection

A safety helmet protects against impacts and blows, but in ATEX zones, you must also consider its electrical properties and compatibility with other PPE. Preferably choose a helmet suitable for the risks in your environment—for example, one with a chin strap where there is a risk of falling or wind load, and with accessories that do not cause sparking or static buildup.

Face protection may be necessary in the event of chemical splashes, pressure relief, sparks from maintenance work, or the risk of flying particles. Match the face shield to the type of risk: chemical splashes require different materials than mechanical impact. Also consider fogging, field of vision, and compatibility with respiratory protection.

Hearing Protection in Noisy Environments

Many ATEX locations are also industrial environments with compressors, fans, pumps, and pneumatic systems. Hearing protection prevents hearing damage but must be selected correctly based on measured dB levels and duration of use. Excessive attenuation can impair communication and the ability to recognize alarms. Practical advice: Use an attenuation calculation and choose earplugs or earmuffs that allow for safe communication, possibly with ATEX-compliant communication solutions where necessary.

Gloves: Chemical Protection and Grip

Gloves used in ATEX zones must be suitable for the substances present and the tasks being performed. Chemical resistance is often the primary consideration, but don’t overlook mechanical risks: cuts, abrasions, punctures, and grip on oily surfaces. It’s important to select gloves based on a list of substances and breakthrough times. There is no such thing as a “universal” glove. 

The same rule applies here: prevent the risk of ignition. In some situations, it’s desirable for gloves to have antistatic properties or, at the very least, not to build up a static charge. Combine this with proper grounding and work methods, especially when handling powders or solvents.

Respiratory protection: FFP, half-face mask, or compressed air?

Respiratory protection in ATEX zones is not just about dust, but also about vapors, mists, toxic substances, and potential oxygen deficiency. FFP masks are suitable for particles, but not automatically for vapors. For vapors, you need filters with the appropriate gas and vapor class, and in situations with unknown concentrations or oxygen deficiency, self-contained breathing apparatus (compressed air) is often the only safe choice.

Note: Explosive atmospheres and respiratory protection also involve material properties and spark prevention. Use only systems that meet the site requirements and ensure a proper fit test where necessary. In practice, a poorly fitting mask is the same as no mask at all.

Explosion-proof clothing: antistatic and appropriate for the fire risk

Clothing is crucial in ATEX zones because textiles can build up electrostatic charge. Antistatic workwear helps dissipate that charge in a controlled manner, thereby reducing the risk of a discharge acting as an ignition source. In many environments, flame-retardant clothing is also essential to minimize injuries in the event of a flash fire or heat radiation.

When selecting clothing, pay attention to the correct standards and the big picture: undergarments, the layering principle, fit, and maintenance. Incorrect detergents or the use of the wrong undergarments can reduce antistatic properties. Also important: clothing must be worn fully closed as intended; otherwise, its protective value decreases.

Footwear: ESD, antistatic, and safe walking

Safety shoes in ATEX zones must not only protect against impact and penetration but also help manage electrostatic risks. Antistatic footwear or ESD footwear can help dissipate static charge, provided the floor and the entire system support this. In addition, slip resistance, chemical resistance, and comfort are key factors, especially when walking long distances or on wet floors.

Practical pitfall: new shoes on an insulated floor, combined with layers of synthetic clothing, can still lead to static buildup. So always consider the entire situation and not just a single product feature.

Which standards and markings are relevant for ATEX and PPE?

ATEX and Explosion Safety: EN IEC 60079 Series

The EN IEC 60079 series serves as an important foundation for the explosion safety of electrical installations and equipment. EN IEC 60079-0 is the general standard for explosion-proof equipment. In the workplace, this translates to requirements for the use of Ex equipment, inspections and maintenance, and avoiding the use of uncertified tools in the zone.

Practical note: The standard texts themselves are often behind a paywall (NEN/IEC), but the legal frameworks that reference them are publicly available. Therefore, at a minimum, keep track of the official guidelines (ATEX 153/114 via EUR-Lex) and document in your EVD which standard versions you are using.

Antistatic Properties: EN 1149 and ESD in Context

EN 1149 is a core standard for antistatic protective clothing. This standard addresses electrostatic properties and helps limit spark discharges. Important: antistatic clothing is only one measure. Grounding, flooring, footwear, humidity, and work methods all play a role in determining whether you are effectively managing static risks.

CE Marking: Mandatory, but Not the Whole Story

PPE must bear the CE marking and comply with the relevant product standards under the PPE Regulation. CE marking is a minimum requirement: it indicates that the product meets European requirements, but does not automatically mean it is suitable for your specific ATEX zone, substances, and work process. That is why a task-risk analysis and proper PPE selection remain essential.

Zones 0/1/2 and 20/21/22: What Does This Mean for PPE?

The zone determines how stringent you must be in preventing ignition sources and in controlling the use of materials. In Zones 0 and 20, the risk of an explosive atmosphere is continuous or long-term. There, tolerance for errors is minimal, and measures must be robust. In Zones 2 and 22, an explosive atmosphere does not normally occur, or only occurs briefly. This does not mean you can be less careful, but rather that your measures are often more focused on incidents and deviations. 

Application to PPE: In higher-risk zones, you generally want to enforce stricter requirements for antistatic clothing, a controlled chain of footwear and flooring, no unsuitable materials, and stricter procedures regarding the bringing in of personal items such as phones or accessories.

Working with ATEX PPE: What Should You Keep in Mind?

Start with the explosion safety document and the task-risk analysis

A PPE list “for the site” is often too generic. Proper selection starts with the explosion safety document, the zoning, the substances involved, and the specific work activities. Maintenance in a pump room requires different equipment than sampling at a tank farm or filling big bags in a dust zone. 

Practical tip: Create a one-page “PPE + Explosion Safety Behavior” guide for each core task and link it to your work permits. This helps contractors and your own employees know at a glance what is and isn’t allowed.

Training, Instruction, and PPE Compliance

In ATEX environments, PPE compliance is no minor detail. An open zipper, an unfastened cuff, or an improperly secured filter can make all the difference. Train employees on why the rules exist, not just what the rules are. Combine this with clear work instructions and supervision, especially for contractors and temporary staff.

Inspection, maintenance, and service life

PPE wears out. Elastic bands stretch out, filters become saturated, antistatic properties diminish due to improper cleaning, and visors get scratched. Establish how often you inspect, how you record findings, and when you replace items. Keep it practical: checklists at distribution points and simple criteria for rejection are more helpful than a procedure that no one uses.

Compatibility: PPE as a system

The combination of a helmet, goggles, hearing protection, and a respirator must be both comfortable and provide a tight seal. A half-face respirator that presses against safety goggles can cause leaks. Ear muffs can make the helmet unstable. Test combinations in practice and preferably choose products that work well together as a set.

Common Mistakes When Working in ATEX Zones

• Focusing solely on the CE marking and not on the task, substance, and zone. CE marking is necessary but insufficient as a selection criterion.

• Confusing antistatic with flame-retardant. Antistatic refers to electrostatic discharge, while flame-retardant refers to fire and heat transmission. You often need both, but they are not the same.

• Wearing the wrong layers under antistatic clothing. Synthetic undergarments can increase static buildup or affect the clothing’s properties.

• Lack of attention to housekeeping in dust-prone areas. Dust deposits act as fuel and can increase the risk of explosion.

• No fit test or user instructions for respiratory protection. A mask that doesn’t fit properly does not provide protection.

• Bringing personal items such as non-Ex-certified electronics, metal accessories, or materials that can produce sparks.

When is PPE required in ATEX zones?

PPE is mandatory as soon as risks cannot be sufficiently eliminated through source control measures or collective measures. In ATEX zones, the employer is required to identify risks and implement appropriate measures. If PPE is required, the employer must provide it free of charge, ensure proper instruction, and monitor its correct use. This also applies to temporary workers and contractors: the client must ensure that the requirements on-site are clear and are being followed.

What does the Dutch Labor Inspectorate check in practice?

The Labor Inspectorate typically examines the consistency between policy, documentation, and implementation. For example:

• Is there an up-to-date Risk Assessment and Evaluation (RI&E) and, where required, an explosion safety document with zoning and measures?

• Is PPE appropriate for the risks and available at the workplace?

• Is there demonstrable training and instruction, including supervision?

• Are PPE items maintained, replaced in a timely manner, and stored properly?

• Do work permits, procedures, and actual behavior on the job site align with one another?
  
  

New EN and ISO standards: what has changed, and what do you need to keep up with?

Standards and interpretations continue to evolve. This doesn’t mean you have to replace your entire PPE package every year, but it does mean you should periodically check whether your selection still aligns with the state of the art and current product standards. Especially for respiratory protection, chemical-resistant gloves, and flame-retardant and antistatic clothing, we regularly see updates to testing methods and classifications. Incorporate this into your procurement policies, audits, and toolbox meetings, and ensure that suppliers can provide up-to-date compliance information.

Explosion-safe work requires a systems approach

Working safely in ATEX zones requires a comprehensive system: proper zoning, control of ignition sources, appropriate Ex-rated equipment, sound work procedures, and PPE that mitigates residual risks without itself becoming an ignition source. Those who select PPE based on the task and zone, properly instruct employees, test combinations, and ensure maintenance significantly reduce the risk of incidents and demonstrably operate in accordance with the intent of the regulations.

Would you like to have your PPE set and work procedures assessed for zone, substances, and activities? Then gather the following in advance: (1) the zoning diagram, (2) the list of substances/SDSs, (3) the job descriptions (including maintenance/cleaning), and (4) your current PPE specifications.