What is the difference between primary, secondary, and tertiary explosion protection?

Primary protection aims to prevent formation of an explosive atmosphere (e.g. by inerting). Secondary protection avoids effective ignition sources (e.g. by using Ex-rated equipment). Tertiary (constructive) protection limits the effects of an explosion (e.g. by pressure relief).

Who is allowed to prepare an explosion protection document?

The employer is responsible for preparing the explosion protection document but may draw on qualified experts. The preparers must have comprehensive knowledge of the relevant regulations, standards, and plant technology.

What does the marking 'Ex II 2G Ex db IIC T4 Gb' mean?

This is an ATEX marking. 'II' — use in industrial (not mining) areas. '2G' — suitable for Zone 1 (gas). 'Ex db' — type of protection (flameproof enclosure). 'IIC' — gas group (e.g. hydrogen). 'T4' — temperature class (max. surface temperature 135 °C). 'Gb' — Equipment Protection Level.

Explosion Protection

Preparation of explosion-protection documents, ATEX hazardous-area classification and periodic inspections by qualified inspectors — standards-compliant with §6 GefStoffV, BetrSichV and IEC 60079.

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What is explosion protection?

What is it?

Explosion protection covers all measures that prevent explosions or reduce their effects to an acceptable level. It is required in areas where flammable substances — gases, vapors, mists, or dusts — can form explosive atmospheres with air.

Why does it matter?

Legal regulations such as the German GefStoffV and the ATEX operator directive 1999/92/EC (ATEX 137) require operators to implement explosion protection measures. A sound explosion protection concept is essential to protect employees, the public, and the plant from the devastating consequences of an explosion.

Your advantage with IOTECH

Our TÜV-certified explosion protection experts bring decades of experience and support you comprehensively — from creating the explosion protection concept to detailed planning and selecting suitable equipment and systems.

Our explosion protection services

Three core areas for comprehensive safety — from documentation through implementation and testing.

Explosion protection documents

Consulting, creation, and ongoing maintenance of the explosion protection hazard assessment per §6 of the German GefStoffV.

Equipment selection & planning

From selecting suitable equipment (protection classes) to detailed implementation planning and the intrinsic-safety proof in your plant.

Test concepts & plans

Concept development and advice on suitable test plans for recurring inspections per §16 BetrSichV and IEC 60079-14.

Application areas

We are your partner for explosion protection across a wide range of industries.

Chemical & petrochemical

Handling of flammable solvents, gases, and dusts.

Pharma & food

Processing of organic dusts (e.g. flour, sugar, active ingredients).

Paint & coating

Use of solvent-based paints and powders.

Energy & waste

Biogas plants, wastewater treatment, and waste-to-energy plants.

Standards & directives

Our work is based on the most current European and national regulations.

ATEX product directive 2014/34/EU
ATEX operator directive 1999/92/EC
German GefStoffV (hazardous substances ordinance)
German BetrSichV (operational safety ordinance)
TRBS / TRGS series (e.g. TRGS 720)
EN 60079 series (electrical apparatus for gas- and dust-explosive atmospheres)

Frequently asked questions

Key information about explosion protection, briefly and clearly explained.

Free explosion-protection tools

Use our online calculators for quick pre-assessments — directly in the browser, no signup required.

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Intrinsic-safety proof calculator

Verify the combination of intrinsically safe circuits per IEC 60079-25. Automatic assessment of Ui/Ii/Pi, Ci and Li with PDF export for your documentation.

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Free

Ex-marking decoder

Interactive explainer for ATEX markings per IEC 60079-0. Understand equipment group, category, protection type, temperature class and gas group at a glance.

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Reference projects

Discover successful projects and real-world applications of our Explosion Protection expertise in industry.

Real-world examples from industry

See how we have successfully tackled complex challenges in Explosion Protection. Our case studies show concrete approaches and measurable results.

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Related services

Combine explosion protection with other services for a comprehensive safety concept.

Functional Safety

Integration of safety-instrumented systems in hazardous areas.

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I&C Engineering (EMSR)

Selection and planning of Ex-i circuits and other explosion protection measures.

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Condition Monitoring

Condition monitoring to avoid ignition sources from mechanical defects.

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Contact us about Explosion Protection

Fill out the form to request a non-binding consultation or to discuss your project with our experts.

Or contact us directly:

info@iotech-automation.de