ATEX project support – get explosion protection decided at the design stage, not after the machine arrives
A new machine, a solvent-based or dusty process, an extension: explosion protection requirements are cheapest to get right during design and procurement. We support the project in three packages – from preparation and, if needed, all the way to the Ex inspection before commissioning.
To start, the machine quotation, the manufacturer's documentation, the safety data sheets and a layout drawing are enough.
One line in the design becomes a rebuild once the machine has arrived
The ATEX questions of a new machine or process – where the extraction goes, how big the zone will be, what type of electrical installation is needed, whether an antistatic floor is required – are still a decision at the design stage. Discovered just before commissioning, they mean delays, rebuilding and expensive replacement of Ex equipment.
Expensive later
Late rework, replacing unsuitable electrical equipment, delayed commissioning – at the most expensive moment of the investment.
Manufacturer certification is not enough
The machine's ATEX certification covers the product. Explosion protection of the surroundings, the supporting systems and the workplace is the operator's obligation.
What's left out of the supply
Flooring, fire suppression, solvent supply lines, earthing and earthing measurement, extraction discharge: these are often not in the manufacturer's scope – yet they are part of the zone.
The manufacturer's ATEX certification and the operator's obligation are not the same
Product side – the manufacturer's
Directive 2014/34/EU, in Hungary NGM Decree 35/2016 (IX. 27.). It covers the design, manufacture and conformity of equipment used in potentially explosive atmospheres. It is addressed to the manufacturer; the result is the EU declaration of conformity and the marking.
Workplace side – the operator's
Directive 1999/92/EC, in Hungary Decree 3/2003 (III. 11.) FMM–ESzCsM. It covers risk assessment, hazardous area classification and the explosion protection document of the workplace. It is addressed to the employer.
What we see again and again when a new machine is introduced
- The manufacturer's zone drawing was made for a similar but different configuration – the one for your machine has to be requested separately.
- Auxiliary units (washing, dosing, mixing systems) bring their own zone, while the lines feeding them remain the operator's responsibility.
- Extraction and supply air clash with the layout, or the discharge point creates a new zone on the roof or façade.
- A dust-handling unit (powdering, filter, extraction) adds a dust explosion risk alongside the gas side.
- With installation on an upper floor or mezzanine, vapours heavier than air can migrate downwards through floor openings and stairwells.
- Electrostatic charging (reels, films, antistatic floor, earthing) gets lost at the boundary between the manufacturer's supply and site construction.
How far do we support the project?
The three packages differ in how far into the investment and at what depth we work. The green label shows which package covers each phase.
1. Decision and procurement
Review of the manufacturer's quote, documentation, materials and installation site.
2. Design
Zone proposal and explosion protection requirements for the designer.
3. Designer and manufacturer meetings
Clarifying open points: zone drawing, declaration of conformity, markings.
4. Tender and construction
Ex-focused comparison of contractor bids, check before acceptance.
5. Commissioning
Initial Ex inspection to EN 60079-17 on the installed equipment.
6. Operation
Explosion protection document and ongoing compliance – a separate service.
Choose how deep and how far we support you
All three packages aim to put the explosion protection requirements on the table during design and procurement. The difference is the method (documents and a short walkdown ↔ measurement and calculation) and the time span (preparation ↔ throughout the project).
ATEX Project Start
Know what to watch for in design and procurement – from the documents, quickly.
For: a smaller modification, one machine or one room, when the designer is already in place.
ATEX Project Plan
A measured, calculated zone proposal and discipline-specific requirements – before the designer and contractor start.
For: procurement of a new machine or process, where zone size and construction cost matter.
ATEX Project 360
Support from design to commissioning – so the planned zone and the installed equipment match.
For: larger investments, several disciplines and contractors, a tight commissioning deadline.
For the technical decision – the business takeaway is above, in the cards and the summary.
| ATEX Project Start | ATEX Project Plan · Recommended | ATEX Project 360 | |
|---|---|---|---|
| On-site sessions | 1 short walkdown (approx. 4 hours), no measurements* | 1 survey day: walkdown, air-flow measurement, smoke test, 3D scan* | survey + pre-acceptance check + inspection before commissioning* |
| Documentation | key points of manufacturer and site documents, safety data sheets | full review, missing data requested in writing | + manufacturer question list (zone drawing, declaration of conformity, Ex markings) and follow-up |
| Zone proposal | preliminary, conservative (no measurement – larger zones) | calculated for the governing sources (IEC 60079-10-1/-2), ventilation measured; draft as PDF | calculated for all sources; draft from the 3D survey, PDF + editable DXF |
| Construction requirements | 1 combined requirement list for the designer | technical requirement sheets per discipline (e.g. mixing/storage room, extraction, electrical, piping and earthing) | + decision sheets (e.g. antistatic floor, automatic fire suppression) |
| Current state | gaps seen on the walkdown | itemised gap list with standard references | + priority, deadlines; survey of existing equipment inside the future zone |
| Ignition source analysis (EN 1127-1) | preliminary, process level | source level | equipment level |
| Designer / manufacturer | – | 1 meeting | meetings throughout, until the zone drawing and declaration of conformity are clarified |
| Tender, construction | – | – | Ex-focused comparison of contractor bids; pre-acceptance check with report |
| Ex inspection before commissioning | – | – | initial inspection to EN 60079-17 on the installed Ex equipment |
| Client's task | ventilation data and photos in writing; verifying the zones later is the client's task | obtaining the zone drawing and declaration of conformity from the manufacturer | – |
| For whom | smaller modification, one machine or one room, designer already in place | new machine or process where zone size and construction cost matter | larger investment, several disciplines and contractors, tight commissioning deadline |
* The number and length of on-site sessions depend on the size of the investment – the exact effort is set in the individual quote after the initial call.
We don't put a fixed price on the website – every investment is different. The exact fee is given in an individual quote after the free initial call.
How we work on an investment
Online call
A short, free discussion of the investment: what changes, with which materials, where and on what schedule.
Document request in writing
Machine quotation, manufacturer's zone drawing and declaration of conformity, safety data sheets, layout and ventilation drawings.
Site survey
Walkdown at the installation site and the supporting areas (storage, mixing, extraction, discharge) – with measurements, depending on the package.
Written expert opinion and requirements
Zone proposal, gap list, construction requirements and schedule – usable by the designer and contractor.
Support to commissioning (Project 360)
Meetings, contractor bid comparison, pre-acceptance check, initial Ex inspection.
Introducing a new machine or process?
Tell us briefly what is changing and send what you already have – the machine quotation, the manufacturer's documentation, the safety data sheets. We will get back to you within two business days.
Frequently asked questions
When should we bring in an ATEX expert?
As early as possible: when selecting the machine or right after ordering it, while the installation location, extraction, electrical supply and room layout can still be changed. At that point a requirement is one line in the design – after the machine arrives it means rebuilding.
The manufacturer supplies an ATEX-certified machine. Do we need anything else?
Yes. The manufacturer's certification covers the product (Directive 2014/34/EU, in Hungary NGM Decree 35/2016 (IX. 27.)) and is addressed to the manufacturer. Workplace explosion protection – hazardous area classification, the explosion protection document, the surroundings and supporting systems – is the operator's obligation (Directive 1999/92/EC, in Hungary Decree 3/2003 (III. 11.) FMM–ESzCsM). One does not replace the other; both are mandatory.
What is the difference between the three packages?
Depth and time span. Project Start tells you what to watch for, based on documents and a short walkdown. Project Plan provides a concrete zone proposal and discipline-specific requirements based on measurement and calculation. Project 360 accompanies the project from designer meetings through contractor bid comparison to the Ex inspection before commissioning.
Is the explosion protection document (EPD) included?
No. Project support covers the preparation and follow-up of the investment. The final hazardous area classification and the explosion protection document are a separate order – for that we offer three packages (Compliance, Verified, FullCare 360).
Do you also do design or construction?
No. We specify and review: we set the explosion protection requirements and review the designer's and contractor's solutions. Design is the designer's job and construction the contractor's; we don't carry out repairs affecting Ex equipment (EN 60079-19) either. This keeps our opinion independent.
We want to convert an existing machine to solvent-based materials. Is that simpler than a new machine?
Usually not – often it is harder. A conversion brings no new manufacturer documentation, the original conformity covers the previous use, and the modification typically shifts responsibility to the operator. A more thorough survey is needed; we flag this in the quote up front.
How much does it cost?
There is no fixed price on the website, because every investment is different. The fee is given in an individual quote after a free online call – and, if needed, a short preliminary site walkdown. 50% of the fee for the preliminary walkdown is credited to the chosen package within 12 months.
How long does it take?
The written expert opinion for Project Start and Project Plan is typically ready within a few weeks of receiving the documents. Project 360 covers the whole investment, from ordering the machine to commissioning.