When transporting grain, feed, sugar, wood dust, plastics, or other dust-containing bulk materials, explosive dust-air mixtures can form in conveying systems. Elevators often connect multiple areas of the system. Therefore, a fire or explosion can quickly spread to other parts of the system through the conveying technology.
The Association of German Engineers published the completely revised guideline in June 2026.VDI 2263 Sheet 8 "Dust Fires and Dust Explosions – Hazards – Assessment – Protective Measures – Fire and Explosion Protection in Elevators" It replaces the previous edition from December 2008 and describes the current state of the art for the safe planning and operation of corresponding conveying systems.
Which conveying systems are considered?
Elevators are considered in this context as vertical conveyors that transport bulk materials between different heights. The guideline specifically addresses:
Bucket elevators
Inclined or Z-bucket conveyors
Pendulum bucket systems
Wave edge conveyors
The principles described can also be applied to comparable conveyor systems according to VDI.
Why is there a particular danger with elevators?
A dust explosion fundamentally requires a combustible dust, oxygen, a sufficiently high dust concentration, and an effective ignition source. In closed conveyor systems, these conditions can occur simultaneously.
Possible ignition sources include:
overheated bearings or drive components
friction from misaligned belts
rubbing or blocked components
entrained foreign bodies
mechanically generated sparks
electrostatic discharges
inappropriate electrical equipment
glowing nests in the conveyed material
Elevators can also connect different areas of a facility. Without appropriate decoupling measures, there is a risk that pressure waves, flames, or burning material can spread to connected silos, filters, conveyor lines, or production facilities.
Manufacturers and operators bear different responsibilities.
VDI 2263 Sheet 8 explicitly considers both the responsibilities of manufacturers and the obligations of operators. It follows the European distinction between material and operational requirements.
For manufacturers of devices and protective systems, the directive 2014/34/EU, often referred to as the ATEX Product Directive, is particularly relevant. Operators of explosion-prone areas, on the other hand, must primarily observe the operational requirements of the directive 1999/92/EC and its national implementation. In Germany, this includes, among other things, the Hazardous Substances Ordinance and the Operational Safety Ordinance.
The new VDI guideline emphasizes that measures against fires and explosions must not only be considered after commissioning. They must already be taken into account during the planning and construction of the facility.
What should operators check now?
The publication does not automatically mean that every existing facility must be modified. VDI guidelines are fundamentally advisory in nature, but they serve as important orientation to the recognized rules or the state of the art.
Since risk assessments must be regularly reviewed and adjusted considering the current state of the art, operators should take the new edition as an opportunity to review existing protection concepts.
The following points should be considered, among others:
Properties of the bulk material
Is the material flammable? What safety-related parameters are available? Can finer or drier dust fractions form during transport?
Formation of explosive atmosphere
In which areas of the elevator can dangerous dust concentrations occur? Are start-up and shut-down processes, disturbances, and cleaning activities also considered?
Possible ignition sources
Are bearings, belt operation, speed, and temperature adequately monitored? Can foreign objects, friction, electrostatic charging, or hot surfaces trigger an ignition?
Preventive explosion protection
Can dust release and deposits be reduced? Are suitable and correctly labeled operating resources used?
Constructive explosion protection
Are pressure relief, explosion suppression, explosion-proof construction, or a combination of these measures required?
Explosion technical decoupling
Is it prevented that an explosion transmits to connected plant parts?
Fire early detection and shutdown
Are temperature increases, speed deviations, belt misalignment, or smoldering spots detected in time? Is it clearly defined how the system is shut down in case of danger?
Cleaning, maintenance, and documentation
Are there mandatory cleaning intervals? Are dust deposits, wear, and safety-relevant changes documented?
Explosion protection document still crucial
If hazardous explosive mixtures are identified in the risk assessment, the employer must specifically indicate this in an explosion protection document. It must also be clear that the explosion hazards have been identified and assessed, and suitable protective measures have been established.
The Hazardous Substances Ordinance also requires that fire and explosion hazards be avoided as much as possible or at least reduced as much as possible. Technical protective measures take precedence over organizational and personal measures.
An update may be particularly necessary if:
new bulk materials are processed,
material properties or dust content change,
throughput quantities are increased,
modifications or expansions take place,
protection or monitoring devices are changed,
new safety-related findings are available,
disruptions, fires, or near-miss incidents have occurred.
Safe inspection in explosion-prone areas
Regular visual inspections, maintenance work, and documentation of damages are also part of an effective protection concept. If employees need to enter explosion-prone areas, the tools used must not present an additional ignition source.
This includes, for example:
explosion-proof handheld and work lights
ATEX smartphones and tablets
explosion-proof cameras
suitable communication devices
mobile measuring and testing devices
With explosion-proof mobile devices, for example, nameplates, dust deposits, damaged housings, leaking connections, or noticeable bearing points can be documented directly on site. It is crucial that the device category, explosion group, temperature class, and device protection level match the respective zone classification.
Conclusion
With the VDI 2263 Sheet 8 published in June 2026, manufacturers, planners, and operators have an updated technical basis for fire and explosion protection in elevators. The focus is on a holistic concept: from the knowledge of the conveyed goods to the avoidance of effective ignition sources to the limitation and decoupling of possible explosions.
Operators of corresponding conveying systems should therefore check whether their risk assessment, the explosion protection document, the operating instructions, and the implemented protective measures still comply with the current state of the art.
ATEXshop.de offers explosion-proof smartphones, tablets, cameras, lights, and communication solutions for inspections, maintenance work, and documentation tasks in explosion-prone areas.