Hazardous location lighting is lighting equipment specifically designed for environments where flammable gases, combustible dust or explosive vapors exist. It must comply with strict safety standards such as UL 844, ATEX and IECEx.
In high-risk industrial scenarios such as oil & gas, chemical plants, and grain processing, the use of compliant lighting fixtures is not only related to worker safety, but also to regulatory compliance and continuous operation.
This article will help you understand the certification standards, the regional division system, and how to select the appropriate hazardous location lighting solution.
Hazardous location lighting refers to specialized lighting designed for hazardous environments with explosion risks, where standard fixtures may become ignition sources and pose serious safety threats.
The primary safety function of hazardous area lighting is not just illumination, but preventing the fixture from becoming an ignition source. It must possess the following capabilities:
● Explosion-proof: It can withstand possible explosions inside and prevent the spread of flames to the external environment.
● Limit surface temperature: Ensure that the maximum surface temperature of the lamp housing is lower than the ignition point of the surrounding hazardous gases.
● Prevent sparks: Through special design, avoid generating electric sparks during normal or abnormal operations.
In industrial sectors including petrochemicals, mining, and grain processing, lighting plays a vital role in both productivity and safety. In Class I, II, and III hazardous locations or Zone-classified areas, standard lighting equipment may act as an ignition source, posing substantial fire and explosion risks.
● Fire and explosion risks: In hazardous environments, even the slightest energy can trigger electric sparks, heat accumulated on high-temperature surfaces, or mechanical shocks.
● Potential ignition sources: Industrial environments are filled with various flammable media, such as gasoline vapors, natural gas, and hydrogen.
● Compliance requirements: Certified explosion-proof lighting that complies with standards such as UL 844, ATEX, and IECEx is designed to eliminate ignition sources and ensure regulatory compliance. In contrast, non-compliant equipment may lead to production shutdowns.
Even the most advanced hazardous location lighting equipment may fail if they are not properly identified and classified. Therefore, proper hazard classification is a critical step in lighting selection. In different industrial processes, the probability of release, duration of presence, and physical properties of hazardous substances vary considerably.
Currently, there are two main classification systems for hazardous locations worldwide. Although they share the same goal, they differ significantly in their regional division logic and naming conventions.
Division classification indicates how likely hazards are present and helps determine the required equipment protection level.
| Division | Definition | Examples |
|---|---|---|
| Division 1 | Ignitable concentrations of hazardous materials are present under normal operations or during frequent maintenance or equipment failure. Because of the continuous or likely presence of hazards, more robust, explosion-proof equipment is required. | Locations near fuel pumps where gasoline vapors are commonly present during fueling; Mixing or reaction vessels where volatile chemicals are handled regularly. |
| Division 2 | Hazards are present only under abnormal conditions, such as accidental leaks or container failures. Because of this limited exposure, less stringent protection requirements typically apply. | Areas adjacent to chemical tanks, storage rooms, where flammable gases, vapors, or combustible dust may be released only in the event of a container leak or equipment failure. |
The zone system is an IEC‑aligned classification method used in NEC or CEC as an alternative to the division system, particularly for new or international projects. However, in North America, only gas/vapor zones (Zone 0, 1, 2) are recognized; dust Zones (Zone 20, 21, 22) are not yet formally applied.
| Zone | Description | Examples |
|---|---|---|
| Zone 0 | An explosive gas atmosphere is present continuously or for long periods. | Inside tanks, pipelines, vapor spaces. |
| Zone 1 | An explosive gas atmosphere is likely in normal operation. | Near vent points, around pumps or valves. |
| Zone 2 | An explosive gas atmosphere is unlikely in normal operation, or only for a short duration if it occurs. | Areas around sealed equipment that might leak if damaged. |
Tips: Division vs Zone System
Understanding the classification logic of these two systems is not only a prerequisite for compliant design but also the first step in ensuring that lighting equipment in hazardous locations is selected correctly and provides effective protection.
| Frequency of Hazard Occurrence | Division | Zone | Description |
|---|---|---|---|
| Continuous / Frequent | Division 1 | Zone 0 | Hazard is always or continuously present. |
| Likely in Normal Operation | Division 1 | Zone 1 | Hazard is expected during normal operations. |
| Abnormal Conditions Only / Rare | Division 2 | Zone 2 | Hazard is not expected normally, only if something goes wrong (e.g., leak or failure). |
Groups define the specific type of hazardous substance in the area.
● Groups A-D relate to flammable gases and vapors (Class I)
● Groups E-G relate to combustible dusts (Class II)
| Group | Hazard Type | Typical Examples |
|---|---|---|
| Group A | Acetylene | Acetylene gas in industrial gas plants |
| Group B | Hydrogen, Butadiene | Hydrogen manufacturing, butadiene processing |
| Group C | Ethylene, Cyclopropane | Ethylene plants, chemical processing |
| Group D | Propane, Gasoline, Natural Gas | Refineries, fuel storage, paint spray booths |
| Group E | Metal dusts | Grain handling with metal dust, metalworking |
| Group F | Coal dust | Coal mines, coal handling facilities |
| Group G | Agricultural dusts (e.g., grain, flour) | Grain elevators, flour mills |
T-Code indicates the maximum surface temperature a fixture can reach in service. T1 is the hottest and T6 is the coolest. Must be below the ignition temperature of the hazardous material to ensure the fixture won’t ignite gases, vapors, or dust that are present in the area. T4 is common for many Class I Division 1 areas.
| T-Code | Maximum Surface Temperature | Typical Applications |
|---|---|---|
| T1 | 450 °C (842 °F) | General industry, less sensitive gases |
| T2 | 300 °C (572 °F) | Chemical plants with higher ignition temperature vapors. |
| T3 | 200 °C (392 °F) | Paint spray booths, fuel terminals, refineries. |
| T4 | 135 °C (275 °F) | Most petrochemical facilities, oil rigs, and natural gas processing. |
| T5 | 100 °C (212 °F) | Pharmaceutical plants, fine chemical manufacturing. |
| T6 | 85 °C (185 °F) | Environments with extremely low ignition temperature gases (e.g., carbon disulfide storage). |
Area classification defines the type of hazardous material that may be present and the likelihood of its presence. This ensures the selection of appropriate equipment and safe installation practices.
| Class | Hazard Type | Examples |
|---|---|---|
| Class I | Flammable gases or Vapors | Oil refineries, chemical plants, gasoline storage, paint spray booths |
| Class II | Combustible Dusts | Grain elevators, flour mills, sugar plants, food processing |
| Class III | Ignitable fibers/flyings | Textile mills, sawmills, and woodworking facilities |
Understanding these standards and certifications is the key to choosing the right lighting fixtures for different hazardous areas. The table below lists common certifications and standards for hazardous lighting.
| Certification | Scope / Purpose |
|---|---|
| UL 1598 (Wet Location) | Safety standard for general lighting fixtures designed for wet or damp environments. |
| CSA 22.2 No. 250 | The Canadian standard is equivalent to UL 1598 for general lighting fixtures. |
| UL 844 (Hazardous Locations) | Standard for lighting equipment installed in hazardous classified areas. |
| CSA 22.2 No. 137 | The Canadian standard is equivalent to UL 844 for hazardous location lighting. |
| UL 1598A (Marine Outside Type) | Standard for lighting fixtures designed to withstand harsh marine environments (salt spray, moisture, vibration). |
The following guide helps you quickly determine what type of hazardous location lighting fixtures to choose. Here are some selection factors you need to consider.
● Industry environment: Identify the type of industrial environment where the lighting will be installed. The hazard levels of different environments vary, so lighting fixtures need to be selected accordingly.
● Hazardous substance type: Determine what the main hazardous substances present in the area. It could be gas, vapor, dust or fibers.
● Mounting height: Select the luminous flux and beam angle based on the fixture's mounting height. Higher mounting heights require greater brightness and a wider light distribution angle. At a low height, you can choose a lower power and soft light.
● Required brightness: Insufficient brightness can affect safe operation. The operation area requires higher brightness, while the walkways or corridors can have moderate lighting.
● Certification compliance: Confirm the international certifications that the fixtures must meet, such as ATEX , IECEx, UL 844, and NEC.
● Maintenance cost consideration: Choose fixtures that have a long lifespan, high energy efficiency and are easy to replace. High-quality lighting reduces downtime, lower maintenance frequency, and minimizes total lifecycle costs.
By evaluating the industry environment, types of hazardous substances, installation height and certification requirements can ensure compliant product selection, improve cost control, and enhance overall site safety.
LEDVANCE offers a variety of LED hazardous location lighting fixtures. Each type of lamp is suitable for different hazardous locations and meets different usage requirements.
Hazardous high bays are designed for extreme industrial environments, with no compromise on safety and durability. They feature a copper-free aluminum housing and corrosion-resistant components, and an explosion-proof structure to prevent the ignition of flammable materials. They offer a variety of flexible installation options, including surface, wall, and column mounting, and are compatible with existing Crouse-Hinds Champ™ products.
Product Ratings:
● UL844 Hazardous Locations | CSA 22.2 No. 137
● Class I Division 2, Group A, B, C, D
● Class II Division 1, Group E, F, G
● Class II Division 2, Group F, G
● Class III
●UL 1598 Wet Location | CSA 22.2 No 250
● IP66
● IK08
This LED linear luminaire for hazardous locations features a SUS304 stainless steel housing and is specifically designed for high-risk industrial environments. It delivers stable, energy-efficient performance under harsh conditions and ensures long-term reliability. Equipped with an angled polycarbonate lens, it provides uniform illumination. A stainless steel hanging rope and ceiling mount are included for quick and easy installation.
Product Ratings:
● UL844 Hazardous Locations | CSA 22.2 No. 137
● Class I, Division 2, Groups A, B, C, D
● Class II, Division 1, Groups E, F, G
● Class II, Division 2, Groups F, G
● Class III
● UL 1598 Wet Location | CSA 22.2 No 250
● UL 1598A Marine Outside Type
● DLC 5.1
● IK08
This LED floodlight is engineered for hazardous, wet, or corrosive environments, providing reliable high-performance illumination. It features a copper-free, corrosion-resistant aluminum shell for robust and durable construction. The explosion-proof structure helps prevent ignition of flammable materials. Tool-free wiring facilitates maintenance, and the adjustable bracket allows for flexible and convenient installation.
Product Ratings:
● UL844 Hazardous Locations | CSA 22.2 No. 137
● Class I Division 2, Group A, B, C, D
● Class II Division 1, Group E, F, G
● Class II Division 2, Group F, G
● Class III
● UL 1598 Wet Location | CSA 22.2 No 250
● UL1588A Marine Locations
● IP66
● IK08
Hazardous Jelly Jar luminaire offers reliable protection in a compact size. It provides various mounting options and lens choices, and features an optional emergency battery pack (EMBB). Its space-saving design makes it ideal for stairwells, walkways, pump rooms, exits, and other industrial environments requiring durable, explosion-protected lighting.
Product Ratings:
● UL844 Hazardous Locations | CSA 22.2 No. 137
● Class I Division 2, Group A, B, C, D
● Class II Division 1, Group E, F, G
● Class II Division 2, Group F, G
● Class III
● UL 1598 Wet Location | CSA 22.2 No 250
● UL1588A Marine Locations
● IP66
● IK08
Across all product types, LEDVANCE designs all hazardous‑location luminaires with a focus on safety while also taking into account energy conservation and durability. Support safe and compliant operations in hazardous areas while reducing risk and maintenance costs.
For detailed specifications, installation instructions, and product demonstrations, please consult the corresponding product manuals and instructional videos.
Hazardous location lighting and explosion-proof lighting are often used interchangeably in the field of industrial lighting, but they are not entirely equivalent concepts.
In simple terms, explosion-proof lighting is a specific type of hazardous location lighting. Explosion-proof means that the lamp itself can withstand an internal explosion and prevent flames or high-temperature gases from spreading outward and igniting the external environment.
Hazardous location lighting is a larger range, including explosion-proof, intrinsically safe, increased safety, dust-ignition proof, and so on.
In conclusion, understanding hazardous location lighting is essential for safe and efficient industrial operations. LEDVANCE offers certified lighting solutions designed for reliability, energy efficiency, and long-term durability. Our expertise ensures that every fixture meets safety standards, helping you protect both personnel and equipment. We will continuously enhance product performance and introduce innovative solutions for new applications.
Explore our full range of products, download detailed manuals, or contact our specialists today to select the right lighting solution for your hazardous location.
Class I Division 1 areas have flammable gases during normal operation, requiring the highest explosion protection, while Division 2 areas only contain gases under abnormal conditions and need a lower protection level.
No. Standard LED fixtures are not designed to prevent sparks, overheating, or faults, and cannot safely install flammable gases, vapors, or dust. Only certified hazardous‑location LED fixtures with correct class, division/zone rating, groups and temperature code can be legally and safely used in these environments.
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