Can industrial LED lighting be used in potentially explosive environments?

Short answer

In an Ex zone, only the ATEX marking that matches the zone counts. A high IP or IK rating never replaces it.

Yes, industrial LED lighting can be used in potentially explosive environments, but only if the luminaires have a valid ATEX certification. Standard LED luminaires are prohibited in these zones, regardless of their IP rating or build quality. In this article you will find answers to the most frequently asked questions about ATEX lighting: from zone classifications and technical operation to certification markings and the difference with IECEx.

0 / 1 / 2

zones for gas, vapour and mist

20 / 21 / 22

zones for combustible dust

highest temperature class: surface no more than 85 °C

Directive 2014/34/EU for the equipment and 1999/92/EC for the workplace. The zone classification follows NEN-EN-IEC 60079-10-1 (gas) and 60079-10-2 (dust).

What JEL does and does not do here

JEL Products has no ATEX certification

We are therefore not the supplier for zones 0, 1, 2, 20, 21 and 22. If your specification calls for ATEX, we say so up front and refer you to a certified Ex manufacturer.

What we do provide is the lighting of the site, the installations and the halls outside the zoned areas, based on the zone map from your explosion protection document. That is where the environmental factors discussed later in this article apply: corrosion, heat, vibration and high-pressure cleaning.

What are ATEX zones and what lighting requirements apply?

Not every industrial environment is the same when it comes to explosion risk. ATEX zones are areas where an explosive atmosphere can occur due to the presence of flammable gases, vapors, mists, or dust. The European ATEX directives divide these areas into zones based on how often and how long an explosive atmosphere is present,and that classification directly determines which lighting you are allowed to use there.

The zone classification determines which protection level is required:

Zone	What applies
Zone 0 / Zone 20:	Explosive atmosphere is continuously or for long periods present. The highest level of protection is required (category 1).
Zone 1 / Zone 21:	An explosive atmosphere occurs occasionally during normal operating conditions. Category 2 equipment is required.
Zone 2 / Zone 22:	Explosive atmosphere is rare and of short duration. Category 3 equipment is permitted.

Zones 0, 1 and 2 relate to gases and vapours. Zones 20, 21 and 22 are intended for environments with combustible dust, such as in the food industry or during the storage of fine powder. Luminaires in each zone must be demonstrably approved for those specific conditions.

How does explosion-proof LED lighting work technically?

The principle may be surprising: explosion-proof lighting does not prevent an explosion, but ensures that the luminaire itself can never act as a source of ignition. This is achieved through specific construction methods that isolate the electrical components from the surrounding atmosphere.

The most commonly used protection concepts are:

Ex d (pressure-resistant enclosure): The housing is constructed so solidly that an internal ignition cannot propagate to the outside.
Ex e (enhanced safety): Electrical connections and components are designed to prevent sparking and overheating.
Ex i (intrinsic safety): The electrical energy in the circuit is so low that ignition is physically impossible.
Ex ec (non-sparking, formerly Ex nA): Used in Zone 2, where the circuit does not produce sparks under normal conditions.

In addition to the protective enclosure, temperature control is crucial. Every ATEX luminaire has a maximum surface temperature, expressed as a temperature class (T1 through T6). This limit must never be exceeded, as the surrounding atmosphere could otherwise still ignite. LED technology has an advantage over traditional light sources in this regard: LEDs produce significantly less heat while providing the same level of light.

What do the ATEX certification markings on a luminaire mean?

That series of letters and numbers on an ATEX luminaire may seem cryptic at first glance, but it is actually a coded description of the approved operating environment. They indicate at a glance for which zone, gas type, and temperature class the luminaire is certified. Correctly interpreting these markings is essential when selecting the right lighting.

A typical ATEX marking looks like this: II 2G Ex db IIC T6 Gb. The parts mean:

II: Apparatus group II, for surface industries (not for mines).
2G: Category 2, suitable for Zone 1 and Zone 2, with G for gas.
Ex: An indication that this pertains to explosion protection.
db: Protection concept flameproof enclosure (d) with protection level b, suitable for Zone 1.
IIC: Gas Group. IIA is for propane, IIB for ethylene, and IIC for hydrogen and acetylene (the most explosive).
T6: Maximum surface temperature of 85 °C.
GB: Protection level for Zone 1 applications.

For environments with combustible dust, a D appears instead of a G (for example II 2D Ex tb IIIC T135°C Db). It is essential that the marking exactly matches the requirements of the zone concerned. IP and IK ratings are complementary to this, but never replace the ATEX marking.

Which industrial sectors use ATEX lighting the most?

ATEX lighting is mandatory in all sectors where flammable substances are present during production, storage, or transport. This involves a wide range of industries, from petrochemicals to food processing.

The sectors with the highest demand for ATEX-certified LED luminaires are:

Oil and gas industry: Refineries, drilling rigs, and pipeline terminals constantly work with flammable gases and liquids.
Chemical industry Production sites involving solvents, acids, or reactive substances almost always fall under ATEX regulations.
Offshore and maritime operations: Ships and platforms with fuel tanks or gas installations require certified offshore lighting.
Harbors and terminals: Storage and transfer of flammable liquids and gases in tank farms and loading stations.
Food industry and pharmaceuticals: Fine organic dust such as flour, sugar, or pharmaceutical powders can form explosive dust clouds (Zone 21/22).
Mining Underground mining with methane gas requires the highest ATEX category.

Local ATEX zones can also be present in heavy manufacturing and recycling companies, for example near spray booths, paint storage areas, or installations with flammable refrigerants.

What is the difference between ATEX and IECEx certification?

Both systems focus on explosion-proof equipment, but the geographical scope differs significantly. ATEX is mandatory within the European Union and is based on EU directives 2014/34/EU and 1999/92/EC. IECEx is an international system of the International Electrotechnical Commission and is recognized outside of Europe, including in Australia, Canada, and the Middle East.

The technical requirements of both systems are largely comparable, but the certification procedures and markings differ. A luminaire with ATEX certification does not automatically comply with IECEx requirements, and vice versa. For projects outside Europe, it is therefore necessary to check which certification is required locally.

In practice, many manufacturers opt for dual certification so that luminaires can be used both in Europe and internationally. This is particularly relevant for companies operating in the port and terminal sector with internationally operating installations.

When is a standard IP65 luminaire not sufficient in an industrial environment?

An IP65 rating says something about protection against dust and water jets, but nothing about the risk of ignition. In ATEX zones, an IP65 luminaire without corresponding ATEX certification is legally insufficient and downright dangerous.

But even outside ATEX zones, there are situations where a standard IP65 luminaire falls short:

Extreme temperatures In environments with heat above 50 °C or cold down to -25 °C, standard luminaires perform unreliably or fail completely.
Aggressive corrosion: Sea air, acids, lyes or chemical vapors rapidly attack ordinary aluminum housings. For these environments, corrosion-resistant lighting made of stainless steel or specially coated material is necessary.
Mechanical shocks and vibrations: Heavy machinery, cranes, and vehicles cause vibrations that damage standard luminaires. A high IK rating is therefore required.
High-pressure washing: In environments where equipment is regularly cleaned with high-pressure washers, IP65 is not sufficient. IP66 or IP67 is then minimally required.

The correct choice of luminaire always starts with a thorough analysis of the environmental conditions, not just the IP rating. Sound knowledge of standards, zone classifications, and material selection is indispensable in this regard.

Site with Ex zones

Send us the zone map and we will light what falls outside it

On a site with tank storage or fuelling points, often only part of it is zoned. We calculate the lighting for the roads, quays, installations and halls outside the zones, and indicate per position where the boundary lies. For the zones themselves, we refer you elsewhere.

Submit your zone map

Free of charge and without obligation · Response within 1 working day from an engineer

Practical example: BUSS Terminal Eemshaven

BUSS Terminal Eemshaven is used for offshore wind logistics and heavy port activities, close to the Wadden Sea area. What started as a lighting question grew into a complete infrastructure project. JEL handled the lighting design, the assessment of light pollution and environmental impact, geotechnical investigation, foundations with 12-metre-deep foundation piles, civil works, power infrastructure, 50-metre lighting masts and the installation of DarkLicht 600 W industrial LED luminaires.

On a site where part of the area is zoned, the same task applies to everything outside the zones. Mast positions, cable routes and aiming angles then have to fit not only the site layout and the required illuminance, but also the boundaries in the zone map. That trade-off belongs in the design, not in the installation phase.

The environmental factors outside the zones do not go away. Coastal conditions, wind load and environmental sensitivity each place their own demands on luminaire, mast and foundation. An ATEX marking says nothing about these, just as a high IP rating says nothing about the risk of ignition inside the zones. For the zones themselves, a certified Ex manufacturer remains the point of contact.

How JEL Products helps on sites with explosion hazard zones

JEL Products has no ATEX certification and does not supply luminaires for the zones themselves. We do light the site areas, installations and halls outside the zoned areas. The approach goes further than supplying a luminaire: the entire process from lighting design to installation and commissioning is supported.

What JEL Products offers on sites with ATEX zones:

Luminaires for the areas outside the zones, including under aggressive chemical exposure
Stainless steel versions for environments with extreme corrosion
Referral to a certified Ex manufacturer for luminaires in the zones themselves
ISO 9001 and VCA** certified working method for safe installation and delivery
Experience in sectors such as offshore, chemical, ports, and heavy industry

Do you have a site with ATEX zones and want to know what lighting is needed outside those zones? Please contact JEL Products for a no-obligation technical discussion.

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