Safe Lifting Technology for Hazardous Areas (ATEX)
In many process-critical industries such as the chemical and pharmaceutical sector, offshore and onshore oil & gas processing, as well as the defense industry, flammable gases, vapors, or dusts can create potentially explosive atmospheres. In these environments, explosion protection is not merely a legal requirement but a key factor for plant availability, process safety, and the protection of people and the environment.
But what does ATEX actually mean in practice—and what role do air hoists play in implementing a safe explosion protection concept? This JDN Insight provides a practical overview.
JDN Product Highlights
Air hoists for ATEX use
Air hoists mini series
The mini is the most compact hoist on the market and, thanks to its integrated NFC tag with service app, is unique in the industry and sets new standards in efficient maintenance.
Air hoists PROFI series
The PROFI series – our extremely robust air hoist, designed for heavy-duty and continuous industrial use.
EH series pneumatic
The EH monorail hoist series – the reliable solution for demanding applications and for handling loads under the toughest conditions.
Crane Systems & Crane Kits
Crane systems and crane kits include explosion-proof overhead travelling cranes, suspension cranes, slewing cranes and rotating cranes.
What Does ATEX Mean for Hazardous Areas?
ATEX stands for “ATmosphères EXplosibles” and refers to the European directives governing equipment and protective systems intended for use in potentially explosive atmospheres. The objective of the ATEX regulations is to ensure that equipment does not become an ignition source when operated in an explosive environment.
For plant operators, this means that hoists, cranes, and other work equipment must be designed, tested, marked, and certified accordingly—tailored to the specific hazard present in the application area. This is particularly relevant for hoists, as they are often used in open processes, operate under harsh environmental conditions, and involve direct interaction with personnel.
ATEX Zones and Classifications: A Practical Overview
ATEX zones define how frequently and for how long a potentially explosive atmosphere may occur:
- Zone 0 / Zone 20
An explosive atmosphere is present continuously or for long periods. - Zone 1 / Zone 21
An explosive atmosphere is likely to occur occasionally during normal operation. - Zone 2 / Zone 22
An explosive atmosphere occurs rarely or only for short periods.
A distinction is also made between gas atmospheres (G) and dust atmospheres (D).
When hoists are used in hazardous areas, the ATEX marking of the equipment is decisive. It provides information on:
- the approved area of use (zone),
- the equipment group and category,
- the temperature class,
- and the type of ignition protection.
For industrial plant operators, this marking is essential to ensure legally compliant and standards-conform operation
Selecting the Right ATEX Certification for Your Hoist
Choosing the appropriate hoist begins with the correct zoning of your plant. Based on this, the equipment must feature the corresponding ATEX certification and marking.
To ensure that your hoist is suitable for use in a specific zone, J.D. Neuhaus offers a practical overview to help determine the correct ATEX configuration. This enables quick and reliable identification of the lifting solution that is suitable for your ATEX zone, meets all legal requirements, and operates both economically and safely.
Air Hoists: Explosion-Protection as Standard
Air hoists offer a decisive advantage: in their standard configuration, they are already suitable for use in potentially explosive atmospheres—without the need for additional, cost-intensive protective measures.
The reason lies in the drive principle itself: compressed air generates no sparks, no hot surfaces, and no electrical ignition sources. As a result, pneumatic hoists inherently meet key explosion protection requirements by design.
Advantages of Air Hoists in ATEX Zones
- No Spark Formation
Compressed air as the drive medium is completely free of ignition sources—a major safety advantage over electric drives. - Cooling Effect
The continuous airflow cools the drive system. Overheating is effectively prevented, providing additional safety in hazardous areas. - Robust and Reliable
Pneumatic hoists operate reliably even under heavy dust exposure, high humidity, aggressive atmospheres, and extreme temperatures. - Cost-Effective Explosion Protection
ATEX protection is integrated as standard. Complex enclosures, special motors, or additional protection systems are not required—reducing investment and maintenance costs. - High Duty Cycle
Pneumatic hoists are designed for continuous operation (100% duty cycle), making them ideal for continuous processes in chemical or energy plants.
Electric Hoists in ATEX Environments: High Effort, High Costs
Electrically driven hoists contain sensitive electronics and electrical components that pose particular risks in hazardous areas:
- Potential Spark Formation
Switching operations or defects can create ignition sources. - Extensive Protective Measures Required
For ATEX zones, special enclosures, protection types, and additional inspections are necessary—resulting in high costs and maintenance effort. - Sensitivity to Environmental Influences
Dust, moisture, or extreme temperatures can impair functionality and reduce operational reliability.
In many cases, electric hoists are therefore only suitable for hazardous areas to a limited extent or with significant additional effort.
Conclusion
ATEX-Compliant Hoists – Safety Starts with the Drive
Explosion protection is not an add-on but an integral part of modern industrial plants. Air hoists from J.D. Neuhaus offer decisive advantages in potentially explosive atmospheres thanks to their inherent safety, robustness, and standard ATEX design. For operators in the chemical, oil & gas, energy, offshore, defense, or food processing industries, this means maximum safety, high plant availability, and reduced life cycle costs.
Do you operate lifting equipment in potentially explosive areas or are you planning a new ATEX application?
Our experts will be happy to advise you on selecting the ideal explosion-proof lifting solution – practical, compliant with standards and tailored to your individual requirements.
