An ATEX-certified tool does not make the entire job ATEX-safe
Using ATEX-certified tools is an important step when grinding, milling or cutting work must be carried out in a potentially explosive environment. But there is an important misconception: an ATEX-certified tool does not automatically make the entire job ATEX-safe.
The certification applies to the tool or tool system under the conditions and terms of use for which it has been tested. Safe work in an ATEX zone therefore always requires a broader view of the workplace, the application, the accessories used and the way in which the tool is operated.
The challenge: ATEX-certified is not the same as an ATEX-safe job
ATEX effectively combines two different areas of responsibility. ATEX 114 (Directive 2014/34/EU) concerns equipment and protective systems intended for use in potentially explosive atmospheres. ATEX 153 (Directive 1999/92/EC), on the other hand, focuses on the safety of workers and the workplace.
That distinction matters.
A certified tool is designed and tested so that, when used as intended, it does not become an unwanted source of ignition. But during an actual maintenance job, many more factors come into play. These include:
- The ATEX zone and the type of explosive atmosphere
- The material being worked on
- The combination of machine, cutter or grinding disc and accessories
- The condition and maintenance of the tool
- Air pressure, rotational speed and any cooling requirements
- Hoses, connections and grounding
- Other work or ignition sources in the immediate area
- The operator’s instructions, training and working method
ATEX 153 therefore requires explosion risks to be assessed as a whole. This means looking not only at the equipment used, but also at potential ignition.
The solution: look at the complete system
The right question is therefore not only:
“Is this tool ATEX-certified?”
But above all:
“Are we using the complete system within the conditions under which it has been found to be safe?”
Certified grinding and cutting solutions come with conditions of use. A different machine, an incorrect rotational speed, an unsuitable air hose or use on a material for which the system has not been assessed may mean that you are operating outside the certified configuration.
Before starting work, therefore check, among other things, whether the zone and application match the product documentation, whether the correct combinations of tools and accessories are being used, and whether all prescribed settings and safety measures are being followed.
In addition, site procedures remain leading. ATEX-certified cold work tools can, for example, prevent the work from having to be carried out as conventional hot work. However, this does not automatically mean that no work permit, risk assessment or additional instruction is required. Where the explosion protection document requires it, ATEX 153 specifically calls for written instructions and a permit-to-work system.
A practical example: the ATEX certification of Allmet Safety Tools
The importance of these conditions of use is clearly demonstrated by the current DNV Type Examination Certificate for the grinding tools from Safety Tools Allmet.
The certificate covers a modular system consisting of tungsten carbide cutters, a grinding disc, and pneumatically driven angle and straight grinders. The same certificate also specifies particular conditions for safe use.
For example, the pneumatic machine must be grounded via a conductive or dissipative air hose, the maximum air pressure is 6.3 bar, and specific machine combinations and maximum rotational speeds are prescribed for certain cutters. The certificate also specifies the materials for which the certified grinding tools have been assessed.
That is not a limitation of the certification. It is precisely what makes good certification valuable: clearly defining how the tool must be used safely.
An ATEX certificate is therefore not a blanket approval for every application. It is the basis for safe use within clearly defined conditions.
What does this mean for your maintenance work?
ATEX-certified tools remain an essential part of safe maintenance in potentially explosive environments. Especially where traditional grinding and cutting methods can produce sparks, high temperatures or other ignition risks.
But the greatest safety benefit is achieved when the tool forms part of a complete working method.
That means: the right tool for the right ATEX zone, used on the right material, with the prescribed accessories and settings, and by operators who know how the system must be used.
That is why, at Allmet Safety Tools, we do not only look at which tool you need. We are also happy to advise on the application, configuration and practical use on site. During our training sessions and live demos, we also show how the tools should be used correctly and efficiently.
Because safe work in an ATEX zone does not begin with a single certificate.
It begins with understanding and controlling the complete application.
