Aluminum is lightweight, stable, and corrosion-resistant – at first glance, it seems ideal for use in industry. However, in explosion-prone areas (Ex zones), the material poses a significant risk: it can generate sparks and thus create ignition sources. Therefore, aluminum is not recommended in safety-critical areas.
⚡ Sparking due to impact and friction
If aluminum comes into contact with rusty steel or iron, thermitic sparks can occur. In this process, aluminum and iron oxide react under heat, generating temperatures well over 2,000 °C – more than enough to ignite explosive atmospheres.
🔥 Thermite reaction as a particular danger
The so-called thermite reaction is known from welding and demonstrates how energetically aluminum can react. Even small impacts or friction are enough in explosive zones to trigger dangerous sparks. That is precisely why aluminum is viewed critically in many explosive regulations.
🧯 Practical examples from everyday life
The problem not only affects obvious components such as housings or tools - but also everyday aids:
- Broom handles made of aluminum
- Shovels with aluminum handles
- Hooks or rods with aluminum handles
If these rods come into contact with steel beams, grids, or machine housings in Ex areas, there is a risk of ignition due to spark formation.
✅ Better alternatives for handles & grips
- Wooden handles: Classic, spark-free and easy to use in many areas.
- Glass fiber reinforced plastic (GRP): Robust, durable and electrically non-conductive - therefore particularly suitable in Ex zones.
- Stainless steel handles: When extreme stability is required - heavier, but safer than aluminum.
These alternatives prevent the uncontrolled sparking that can be caused by aluminum and are therefore clearly preferable for hazardous areas.
📌 Conclusion
Aluminum is practical for many applications – but in explosive zones, it poses a safety risk.
Whether with tools, housings, or seemingly harmless aids like brooms, shovels, and hooks: aluminum handles can create dangerous sparks when in contact with steel.
➡️ Recommendation: Use wood, fiberglass, or stainless steel in explosion-prone areas. These materials are spark-free and ensure the necessary safety.