ATEX and Explosion-Proof Cranes for Hazardous Areas

1. What Is an ATEX or Explosion-Proof Crane?

ATEX and explosion-proof cranes are crane and lifting systems evaluated for safe lifting operations in areas where potentially explosive atmospheres may occur. The purpose is to help prevent ignition risks caused by sparks, hot surfaces, electrical faults, mechanical friction or uncontrolled energy sources during crane operation.

ATEX refers to the European Union regulatory framework for equipment and protective systems intended for use in potentially explosive atmospheres. “Explosion-proof” or “Ex-proof” is a general term used to describe equipment designed with suitable protection concepts for hazardous areas.

However, an explosion-proof crane is not automatically suitable for every hazardous area. Suitability depends on area classification, gas or dust type, temperature class, equipment category, working conditions and applicable standards.

2. What Is a Potentially Explosive Atmosphere?

A potentially explosive atmosphere may occur when flammable gases, vapors, mists or dusts mix with air in certain conditions and an ignition source is present.

Such environments may exist in different industrial facilities, including:

• Oil and gas facilities
• Chemical and petrochemical plants
• Paint and solvent production areas
• Fuel storage and filling facilities
• Food, feed or agricultural facilities with combustible dust
• Mining and mineral processing areas
• Pharmaceutical and cosmetics production
• Energy and process plants

Crane systems used in these areas should be evaluated not only for lifting capacity, but also for explosion risk.

3. ATEX Crane vs Standard Crane: Key Differences

ATEX or explosion-proof crane systems differ from standard cranes because potential ignition sources must be controlled. This is not limited to electrical motors or panels; mechanical, electrical, control and operating conditions should be considered together.

Criteria	Standard Crane System	ATEX / Explosion-Proof Crane System
Operating area	Normal industrial areas	Areas with potentially explosive atmosphere risk
Main risk	Load safety and mechanical/electrical safety	Load safety plus ignition source control
Electrical equipment	Standard industrial equipment	Ex-rated equipment may be required according to area classification
Mechanical design	Based on general working conditions	Friction, hot surface and spark risks should be considered
Control system	Standard control solutions	Ex-suitable controls and safety components may be required
Certification	General product and safety requirements	ATEX/Ex conformity requirements should also be evaluated
Project approach	Capacity, span, load type, duty class	Plus zone, gas/dust group and temperature class

Therefore, selecting a crane for hazardous areas requires a more comprehensive engineering and conformity assessment than selecting a standard crane.

4. Why Is ATEX Zone Classification Important?

One of the most critical points in ATEX crane projects is correct area classification. How often and how long an explosive atmosphere may occur directly affects equipment selection.

Gas/vapor and dust atmospheres are generally evaluated separately. Zone classification is based on the likelihood of an explosive atmosphere being present.

Atmosphere Type	Zone Example	General Meaning
Gas / vapor atmosphere	Zone 0, Zone 1, Zone 2	Classification based on frequency of explosive gas atmosphere
Dust atmosphere	Zone 20, Zone 21, Zone 22	Classification based on frequency of explosive dust atmosphere

This classification should be performed by the employer, facility owner, qualified technical team or relevant specialists. The crane manufacturer or supplier uses this information as technical input for selecting suitable equipment.

Incorrect zone information may lead to incorrect equipment selection and serious safety risks.

5. Key Criteria for ATEX Crane Selection

ATEX crane selection should evaluate standard crane parameters together with hazardous area requirements. Capacity and span are important, but they are not enough for a correct ATEX evaluation.

Selection Criteria	Why It Matters
Crane type	Overhead, gantry, monorail, jib or custom crane configuration should be defined.
Lifting capacity	Determines the maximum load to be handled safely.
Span and lifting height	Required for crane geometry and operating area.
Duty class / operating frequency	Affects component selection and long-term performance.
Zone classification	One of the most critical inputs for hazardous area suitability.
Gas or dust group	Required for selecting equipment suitable for the atmosphere type.
Temperature class	Important for evaluating surface temperature and ignition risk.
Working environment	Humidity, chemicals, corrosion, outdoor use and temperature affect design.
Certification requirement	Depends on project, market and customer specification.

Without these criteria, a reliable technical evaluation for an ATEX crane cannot be completed.

6. Gas and Dust Atmospheres in Crane Selection

Potentially explosive atmospheres are not only related to gas or vapor. In some facilities, combustible dust may also create explosion risk. Therefore, gas/vapor atmospheres and dust atmospheres should be evaluated separately.

Criteria	Gas / Vapor Atmosphere	Dust Atmosphere
Risk source	Flammable gas, vapor or mist	Combustible dust cloud or dust layer
Classification	Zone 0, Zone 1, Zone 2	Zone 20, Zone 21, Zone 22
Equipment evaluation	Gas group and temperature class are important.	Dust group, surface temperature and dust accumulation are important.
Maintenance approach	Sealing, electrical equipment and hot surface control	Dust accumulation, cleaning and surface temperature control
Application examples	Chemical, oil, solvent and fuel areas	Food dust, feed, grain, plastic or metal dust areas

For this reason, the term “explosion-proof crane” alone is not technically sufficient. The exact hazardous atmosphere type should be defined.

7. Electrical and Control Systems in ATEX Cranes

Electrical equipment requires special attention in areas with explosion risk. Motors, brakes, panels, cables, limit switches, sensors, controls and power supply systems should be evaluated according to area classification.

Electrical and control system topics may include:

• Ex-suitable motors and brake systems
• Ex-rated limit switches and sensors
• Ex-suitable control systems
• Cables and connection equipment
• Panel location and protection approach
• Grounding and static electricity risks
• Emergency stop and safety circuits
• Protection classes suitable for the environment
• Maintenance and service access

Electrical system selection should be based not only on voltage or power requirements, but also on hazardous area classification.

8. Mechanical Risks in ATEX Crane Systems

In hazardous areas, ignition risks are not only electrical. Mechanical ignition sources should also be considered. Friction, impact, hot surfaces, overheating, braking effects and moving parts should be included in technical evaluation.

Mechanical risk topics include:

• Wheel and runway compatibility
• Brake system
• Bearings and rotating parts
• Hook and connecting elements
• Friction and impact risks
• Surface temperature control
• Corrosion and chemical exposure
• Maintenance access and lubrication approach
• Suitability of below-the-hook attachments

For this reason, ATEX crane design should include mechanical details as well as electrical equipment.

9. What Information Is Needed for an ATEX Crane Quotation?

For an accurate ATEX or explosion-proof crane quotation, hazardous area information should be shared in addition to standard crane data.

Required Information	Description
Crane type	Overhead crane, gantry crane, monorail, jib or custom system
Lifting capacity	Maximum load to be handled
Span and lifting height	Required for crane geometry
Duty class / operating frequency	Affects component selection
Zone classification	Zone 0/1/2 or Zone 20/21/22 information
Gas or dust group	Required for atmosphere suitability
Temperature class	Required for surface temperature evaluation
Working environment	Humidity, chemicals, corrosion, temperature, outdoor use, etc.
Control preference	Pendant, radio remote, cabin, automation, etc.
Facility information	Process, site drawing, hazardous area documents
Certification need	ATEX, IECEx, customer specification or market requirement
Special load / attachment	Below-the-hook devices also require suitability evaluation

Without this information, the quotation may be technically incomplete.

10. Maintenance and Safe Use of ATEX Cranes

Safe use of ATEX and explosion-proof cranes is not only about correct equipment selection. Maintenance, inspection, cleaning, operator training and documentation are also important for continued safety.

Important maintenance and operation topics include:

• Maintaining the original Ex equipment integrity
• Avoiding unauthorized part replacement
• Checking cables, connections and sealing
• Inspecting brakes, motors and moving parts
• Preventing dust accumulation
• Monitoring surface temperature and overheating risks
• Keeping periodic maintenance and inspection records
• Informing operators and maintenance personnel
• Avoiding unsuitable equipment interventions
• Following hazardous area procedures

Incorrect maintenance or unsuitable part replacement may compromise the safe operating conditions of ATEX equipment.

11. Kalsys ATEX and Explosion-Proof Crane Solutions

Kalsys evaluates ATEX and explosion-proof crane requirements by considering not only lifting capacity, but also hazardous area classification, operating conditions, load type, control system requirements and safety needs.

For overhead cranes, gantry cranes, monorail systems, jib cranes or custom lifting solutions, the ATEX/explosion-proof approach can be technically evaluated according to real site conditions.

12. Frequently Asked Questions

12.1. What is an ATEX crane?

An ATEX crane is a crane system evaluated for use in potentially explosive atmospheres according to relevant ATEX and Ex suitability requirements.

12.2. Can an explosion-proof crane be used in every hazardous area?

No. The exact suitability depends on zone classification, gas/dust group and temperature class. Not every Ex-rated device is suitable for every hazardous area.

12.3. What is the most important information for ATEX crane selection?

Capacity, span and operating frequency are important, but zone classification, gas/dust group and temperature class are critical for hazardous area suitability.

12.4. Are only electrical components important in ATEX cranes?

No. Electrical components are critical, but mechanical friction, hot surfaces, impact, brake systems and maintenance conditions should also be evaluated.

12.5. What documents are needed for an ATEX crane quotation?

Hazardous area classification, zone information, gas/dust group, temperature class, site drawing, operating scenario, capacity and control requirements should be shared.

13. Conclusion

ATEX and explosion-proof cranes require special evaluation for safe lifting operations in areas where potentially explosive atmospheres may occur. The correct crane should not be selected only according to capacity and span; zone classification, gas/dust group, temperature class, control system, mechanical risks and maintenance conditions should be evaluated together.

Kalsys evaluates ATEX and explosion-proof crane systems for industrial facilities with hazardous area risks through a project-specific engineering approach.