Special Applications
How ATEX and IECEx zoning works for forklifts, what the equipment categories mean, and the specification points that decide whether a truck is actually compliant.
Last updated: 11 October 2026
A standard electric forklift is a spark source with a battery, a controller and a set of contactors. In a zone where flammable vapour or dust is present, that is a ignition risk. Explosion protection is not a coating or an option — it is a different machine.
The zones
| Zone | Atmosphere | Presence of hazard |
|---|
| Zone 0 | Gas | Continuously or for long periods |
| Zone 1 | Gas | Likely during normal operation |
| Zone 2 | Gas | Unlikely, and only briefly |
| Zone 20 | Dust | Continuously or for long periods |
| Zone 21 | Dust | Likely during normal operation |
| Zone 22 | Dust | Unlikely, and only briefly |
Most warehouses handling solvents, paints, pharmaceuticals or grain fall into Zone 1, 2, 21 or 22. Zone 0 and Zone 20 are not normally accessible to trucks at all.
Equipment categories and groups
- **Group II** — surface industries (everything except mining)
- **Category 2G / 2D** — equipment for Zone 1 and 21
- **Category 3G / 3D** — equipment for Zone 2 and 22
- **Ex d** — flameproof enclosure; an internal explosion is contained
- **Ex e** — increased safety; no arcs or sparks in normal operation
- **Ex ib** — intrinsic safety; energy limited below ignition level
- **Ex de** — a combination, common on forklift controllers and motors
What to specify on the truck
- **Three-electric system** — controller, drive motor and pump motor all in Ex-rated enclosures
- **Battery compartment** — vented and spark-arrested, or the battery itself in a pressurised enclosure
- **Contactors and fuses** — all in Ex enclosures, not merely covered
- **Wiring** — armoured or conduit-protected, with Ex glands at every entry
- **Forks and mast** — non-sparking material (usually stainless or bronze-faced) where contact with the floor or racking is possible
- **Static earthing** — a continuous path from the frame to the ground, or anti-static tyres
- **Surface temperature** — limited to the ignition temperature of the specific gas or dust on site, which is a T-class number on the plate
- **Sensors and lights** — Ex-rated; this is the most commonly missed item
The paperwork that matters
An explosion-proof truck is not compliant because it has a sticker. Ask for:
- The **Ex certificate** naming the exact model and the marking (for example `Ex de ib mb IIB T4 Gb`)
- The **notified body** that issued it, and its number
- The **temperature class** and gas group, checked against your own hazardous area classification
- The **inspection and maintenance schedule** — Ex equipment needs documented periodic inspection, and the certificate is void without it
If a supplier cannot state the Ex marking for the exact model quoted, do not buy it for a hazardous area.
Need help choosing the right truck?
Send us your load weight, lifting height and aisle width — we will recommend the right model.
Frequently asked questions
When is an explosion-proof forklift required?
Anywhere flammable gas, vapour or combustible dust can reach ignitable concentration. This is a legal requirement, not a preference.
What changes on an explosion-proof truck?
Flameproof motors and electricals, limited surface temperatures, and elimination of mechanical spark risk from forks, wheels and the mast.
Can a standard truck be converted?
No. Explosion protection is a whole-machine certification, and retrofitting is neither compliant nor safe.
