ATEX Certified Solutions: Keeping Communication Safe in Hazardous Sites

In hazardous industrial environments, communication systems are not just operational tools. They are potential ignition sources.

Where flammable gases, vapours or combustible dust are present, any electrical equipment must be designed, selected and installed with strict controls. This is the purpose of ATEX certified solutions. They ensure that communication devices used in classified areas do not introduce ignition risks under normal or fault conditions.

For operators in oil and gas, chemical processing, manufacturing, pharmaceuticals and mining, communication infrastructure must meet regulatory requirements while remaining reliable in demanding field conditions. Compliance is not optional. It is enforceable under European law and monitored by safety authorities.

Understanding ATEX and Its Regulatory Foundation

ATEX refers to the European regulatory framework governing equipment and workplaces in explosive atmospheres.

The primary legislation is Directive 2014/34/EU, which defines requirements for equipment intended for use in potentially explosive atmospheres. The full directive is available via the European Commission:

 

In parallel, workplace obligations are addressed under Directive 1999/92/EC, often referred to as ATEX 137.

In the UK, hazardous area responsibilities and enforcement guidance are published by the Health and Safety Executive (HSE).

 

Hazardous Area Classification

Before selecting communication equipment, a site must be classified into zones based on the frequency and duration of explosive atmospheres.

Gas and vapour zones:

• Zone 0 – Explosive atmosphere continuously or for long periods
• Zone 1 – Likely during normal operation
• Zone 2 – Not likely in normal operation and if it occurs, only briefly

Dust zones:

• Zone 20
• Zone 21
• Zone 22

The zone determines the category and protection method required for any installed communication system.

Why Communication Systems Present Real Risk

Industrial communication devices can introduce ignition sources in several ways:

• Electrical arcs or sparks during switching
• Battery faults or short circuits
• Hot surfaces exceeding ignition temperatures
• Static discharge
• RF energy in certain conditions

In a non-classified environment, these are routine design considerations. In a Zone 1 refinery area or a Zone 21 dust processing plant, they can be catastrophic.

Using non-certified radios, telephones or wireless infrastructure in hazardous areas exposes operators to:

• Explosion risk
• Regulatory breach
• Insurance invalidation
• Plant shutdowns

ATEX certified communication solutions are designed to eliminate or control these ignition mechanisms through specific protection concepts.

Core Protection Concepts in ATEX Communication Equipment

ATEX compliance is not a generic label. It reflects defined protection methodologies.

Intrinsic Safety (Ex i)

Intrinsic safety limits electrical and thermal energy within a device so that ignition cannot occur, even under fault conditions.

This is common in:

• Handheld radios
• Mobile devices
• Portable gas detectors
• Headsets and accessories

Intrinsic safety is widely used in Zones 0 and 1 because it is based on energy limitation rather than containment.

Flameproof Enclosure (Ex d)

Flameproof equipment is designed to contain an internal explosion without allowing flames to propagate into the surrounding atmosphere.

Typical applications:

• Fixed communication stations
• Public address systems
• Control room interface units

This method is often used in Zone 1 environments where higher power systems are required.

Increased Safety (Ex e)

Increased safety prevents arcs, sparks and excessive temperatures through enhanced design measures.

It is commonly applied in:

• Junction boxes
• Terminal enclosures
• Certain fixed communication components

The correct protection concept depends entirely on the zone classification and gas group present.

Understanding ATEX Marking on Communication Equipment

Every certified product must carry a marking that identifies its suitability.

An example marking:

II 2 G Ex ib IIC T4 Gb

This indicates:

• Equipment Group II (non-mining)
• Category 2 (Zone 1 suitability)
• Gas environment
• Intrinsic safety method (ib)
• Gas group IIC (hydrogen and acetylene compatible)
• Temperature class T4 (max surface temperature 135°C)
• Equipment protection level Gb

Misinterpreting these markings is a common compliance failure during procurement.

Certification must be issued by an authorised Notified Body. Reputable certification bodies include organisations such as TÜV, DEKRA and SGS. 

Get more info on IECEx certification

Selecting ATEX Communication Solutions: What Actually Matters

When specifying communication systems for hazardous sites, the focus should go beyond the device itself.

1. Confirm the Site Classification

The zone classification must be formally documented. Equipment selection without validated zoning often results in mismatch and rework.

2. Match Protection Method to Zone

A Zone 2 device is not suitable for Zone 1. A gas-certified device may not be approved for combustible dust.

3. Validate Documentation

Required documents include:

• EU Declaration of Conformity
• Type Examination Certificate
• Installation instructions
• Maintenance guidance

Incomplete documentation is a red flag.

4. Evaluate System Integration

Communication rarely operates in isolation. Consider:

• Interface with control systems
• Integration with emergency shutdown procedures
• Power supply isolation
• Cable routing in classified areas

The system architecture must remain compliant as a whole, not just at device level.

Wireless Communication in Hazardous Areas

Wireless solutions are increasingly deployed in industrial sites, but they introduce additional considerations.

ATEX certified Wi-Fi access points, wireless VoIP phones and push-to-talk systems are available for hazardous zones. However:

• Antenna placement must respect zone boundaries
• Power output and energy storage must remain within certification limits
• Installation must align with hazardous area wiring standards

Wireless infrastructure should be reviewed alongside IT and safety teams to prevent unintended compliance gaps.

Installation and Maintenance: Where Many Sites Fail

Certification alone does not guarantee safety.

Common installation issues include:

• Improper cable gland selection
• Incorrect earthing
• Barrier misconfiguration in intrinsically safe circuits
• Unauthorised device substitution

Periodic inspection is required under ATEX workplace obligations. Equipment must be maintained in accordance with manufacturer guidance and site inspection regimes.

Maintenance records should be retained for audit and regulatory review.

Sector Applications

Oil and Gas

Refineries and offshore platforms rely on certified radios, fixed communication stations and emergency paging systems across Zone 1 areas.

Chemical Processing

Intrinsically safe handheld devices and explosion-proof fixed units are common in blending and storage facilities.

Food and Pharmaceutical Manufacturing

Combustible dust hazards require dust-certified communication devices in processing and packaging areas.

Each environment presents different gas or dust groups, temperature classifications and operational constraints. Equipment must be selected accordingly.

ATEX Communication as a System-Level Responsibility

In practice, many compliance issues arise not from product defects, but from fragmented decision-making.

Selecting certified equipment without reviewing:

• Site zoning updates
• Electrical protection design
• Integration with existing infrastructure
• Inspection planning

creates risk exposure.

ATEX certified solutions must be approached as a structured engineering task rather than a procurement exercise.

A specialist provider typically supports clients through:

• Hazardous area communication assessment
• Certification review and validation
• System architecture design
• Installation oversight
• Ongoing inspection support

This structured approach reduces rework, prevents inspection failures and ensures communication reliability under operational stress.

Final Considerations

Communication in hazardous sites must balance operational clarity with ignition prevention.

ATEX certified solutions exist to control risk in environments where flammable gases and dust are present. Compliance depends on:

• Accurate zone classification
• Correct protection concept selection
• Verified certification
• Proper installation
• Ongoing inspection

For organisations operating in classified areas, communication safety should be engineered deliberately and documented thoroughly. In hazardous environments, assumptions are liabilities.

The standard is clear. The responsibility lies in applying it correctly.

Wavesight: ATEX Certified Communication You Can Rely On

In hazardous environments, communication infrastructure cannot be an afterthought. It must be engineered for compliance, durability and uninterrupted performance. As an established ATEX certified solution provider, Wavesight delivers industrial wireless systems purpose-built for explosive atmospheres where safety standards are uncompromising.

Wavesight’s portfolio of ATEX certified products, including the Scorpion Ex range of industrial wireless connectivity radios, is designed for Zones 1, 2, 21 and 22. These systems enable secure, long-range Ethernet communication for data, voice and video across oil and gas facilities, chemical plants, mining operations and offshore sites. Each solution is developed to meet ATEX and IECEx requirements while supporting real-time monitoring, SCADA networks and critical surveillance infrastructure.

For operators seeking compliant, field-proven hazardous area connectivity, Wavesight combines regulatory alignment with practical deployment expertise, ensuring communication remains stable, secure and fully certified in environments where risk tolerance is zero.