The term "explosion protection document" is currently appearing on the agenda of many companies for the first time – not because it is new, but because operator responsibilities have often been long ignored or misunderstood in practice.
The increasing technologization of production and logistics processes, rising demands from insurers, auditors, and customers, as well as the enhanced integration of international supply chains, are leading companies to recognize their need to catch up and seek reliable working foundations.
Legal Framework
The explosion protection document is a requirement for the operator in Germany and the EU and essentially arises from:
Hazardous Substances Ordinance (GefStoffV) → Basis for Risk Assessment and Documentation
Operational Safety Regulation (BetrSichV) → Requirements for Operations, Inspections, and Maintenance
ATEX Directive 1999/92/EC → Minimum requirements for improving explosion protection for workers
What is crucial is that: The document is not provided or approved centrally, but is created and continuously updated by the operator independently.
Mandatory contents of a complete document
An explosion protection document is only reliable if it reflects the actual operating conditions. This includes at least:
Analysis of the possible explosive atmosphere
Type of hazardous substance (gas, vapor, mist, dust, hybrid mixture)
Frequency and duration of occurrence
Zoning
For gases/vapors: Zone 0 / 1 / 2
For dust: Zone 20 / 21 / 22
Zone plan
Representation in the site plan or floor plan
Without a plan, neither examination nor audit is possible
The plan is not an "addition," but the core of the document
Systematic ignition source assessment
Hot surfaces, electrical sparks, mechanical friction and impact sparks, electrostatics, lightning effects, etc.
It is not about eliminating ignition sources, but rather about managing remaining risks in a controlled manner.
Protective measures
Technical: suitable Ex devices, encapsulation, grounding, temperature and process monitoring, ventilation, pressure-resistant or spark-free construction
Organizational: Operating instructions, release systems, responsibilities, training
Inspection and Maintenance Concept
Derived from EN IEC 60079-17
Concrete inspection intervals, scope of inspections, and designated responsible persons
Missing testing concept creates an additional risk for operational failures and insurance issues
Practical problems that explain the current need
Many companies are asking themselves the same questions:
How do I correctly structure the risk assessment?
How do I create a code-compliant zoning plan?
What risks do I need to document, even if the machine is not electrically operated?
How do I establish a testing concept without internal responsibility conflicts?
What translations are useful if the document is to be used abroad?
The questions show: It's not about more buzzwords, but about craftsmanship, structure, and traceability.
Suitable documents and practical work foundations
The following sources provide stable and generally applicable guidelines and sample structures:
DGUV Information 213-106 – Exemplary Structure, Checklists for Practice
TRBS 1112 (Part 1 & 2) – Methodological Basis for Risk Assessment in Explosion Protection
ZVEI Guideline on Explosion Protection according to 1999/92/EC – Systematic Consideration of Ignition Sources and Measures
Not freely available, but content-wise necessary for the creation:
EN IEC 60079-10-1 / 10-2 – Zone Classification Gas/Dust
EN IEC 60079-14 – Installation of Electrical Equipment
EN IEC 60079-17 – Testing and Maintenance
(A document is only as good as the technical and normative foundations behind it.)
Summary
An explosion protection document is not a standard form, but a company-specific safety document that:
Risks realistically assessed,
Zones clearly defined and visually represented,
describes protective measures in a comprehensible manner and
contains a specific inspection and maintenance concept with responsibilities.
The increasing demand is not arising because the topic has become more complicated, but because companies are increasingly understanding that incomplete documentation leads to real risks – technically, legally, and organizationally.