Over 15 years of experience helping facilities achieve UL844-certified safety in the most demanding industrial environments.

What Are Explosion Proof Lights and Why Your Facility Needs Them

Explosion proof lighting fixtures, commonly referred to as hazardous location lights, are engineered safety systems designed to contain and prevent explosions in hazardous environments where flammable gases, liquids, or combustible dust create ignition risks.

Proper lighting, especially in hazardous environments, is essential for safety, visibility, and operational efficiency. Explosion proof lighting, particularly those utilizing LEDs, ensures reliable illumination while minimizing risks.

What makes a light "explosion proof"? Unlike standard industrial lighting, these fixtures are built to control any internal explosion and prevent it from igniting the surrounding atmosphere. Explosion proof lighting also eliminates the risk of sparks that could ignite flammable materials, further enhancing safety in hazardous areas.

The critical difference: Standard lights can become ignition sources. Explosion proof lights are designed to operate safely even when component failures occur inside the fixture, and modern designs often utilize LEDs for their energy efficiency and durability in extreme conditions.

Applications & Industries Where Explosion-Proof Lighting Is Required

Chemical Processing & Storage Facilities

• Petroleum refineries and storage tanks - Volatile hydrocarbon vapors create ignition risks, making explosion proof lighting essential for preventing fires and ensuring worker safety during maintenance operations in oil refineries.
• Paint spray booths and finishing areas - Vapors from paints and coatings require Division 1 rated fixtures to eliminate ignition sources and maintain safe working conditions for operators.
• Chemical processing plants - Multiple flammable chemicals and varying atmospheric conditions demand certified explosion proof lighting to protect against ignition hazards throughout production areas.
• Food processing facilities - Areas where food ingredients such as grains, sugar, or other combustible dusts are present require explosion proof lighting to prevent ignition and ensure safety in food production environments.

Industrial Manufacturing

• Grain silos and agricultural processing - Combustible grain dust accumulation requires Class II-rated lighting, preventing dust explosions.
• Mining operations (underground and surface) - Methane gas and coal dust present dual explosion risks requiring specialized lighting solutions, ensuring high-quality light output in critical work areas.
• Paper mills and wood processing - Fine wood dust and chemical treatments create combustible atmospheres where explosion proof fixtures prevent ignition and maintain productivity during extended operations.

Energy & Utilities

• Oil and gas refineries - High concentrations of flammable hydrocarbons demand the most robust explosion proof lighting to prevent major incidents that could impact entire communities.
• Offshore drilling rigs - Marine environments with oil and gas vapors require corrosion-resistant explosion proof fixtures that maintain safety while withstanding harsh weather conditions.
• Water treatment facilities - Methane and hydrogen sulfide gases from biological processes create hazardous atmospheres requiring certified lighting to ensure safe facility operations.
• Distilleries and alcohol production - Ethanol vapors during fermentation and distillation processes necessitate explosion proof lighting to prevent fires that could damage product and equipment. Explosion proof lighting is also critical in beverage facilities, where beverage production involves flammable vapors or dust, ensuring safety in beverage environments.

Explosion proof lighting is used in a variety of settings, including laboratories, refineries, fabrication shops, food and beverage facilities, and other environments with extreme conditions such as high temperatures, moisture, and vibrations.

Our customer replaced explosion proof fluorescent fixtures with our 100 Watt 4 Foot Explosion Proof Linear LED Light | 16000 Lumens linear fixtures. Dramatic improvement in light quality when they converted over to LED

How to Determine If Your Location Requires Explosion Proof Lighting

The industry standard process involves evaluating your facility using the NEC hazardous location classification system. In contrast, non hazardous areas, such as residential or office environments, typically do not require explosion proof lighting, as the risk of explosion or fire is minimal. In these locations, standard lighting options are usually sufficient. Our Product Specialists have provided a 3-step checklist to determine if your organization requires explosion proof lights.

Always consult with a professional who has expertise in explosion proof lights to help determine the proper class of your space.

LED Lighting Supply's 3-Step Classification Process

Expert methodology for determining explosion proof lighting requirements

STEP 1: IDENTIFY HAZARDOUS MATERIAL PRESENCE TYPE - What hazardous materials are present? (Categories)

• Class I
  • Flammable gases, vapors, or liquids
  • Examples: Gasoline, acetylene, ethylene
• Class II
  • Combustible dust (≤420 microns)
  • Examples: Grain dust, coal dust, metal dust
• Class II
  • Combustible dust (≤420 microns)
  • Examples: Grain dust, coal dust, metal dust

STEP 2 - DETERMINE PRESENCE FREQUENCY - How often are materials present? (Divisions)

• Division 1
  • Present continuously or frequently during normal operations
  • Risk Level: HIGH
• Division 2
  • Present only during abnormal conditions or equipment failure.
  • Division 2 means that ignitable concentrations are unlikely during normal operation.
  • Hazardous materials are only present if something goes wrong.
  • Risk Level: MODERATE

STEP 3 - SELECT GROUP CLASSIFICATION - What specific material group applies?

• Class I Groups:
  • Group A: Acetylene
  • Group B: Hydrogen
  • Group C: Ethylene
  • Group D: Gasoline/Propane
• Class II Groups:
  • Group E: Electrical-conductive dust
  • Group F: Carbonaceous dust
  • Group G: Agricultural/polymer dust
• Class III Groups:
  • No group classifications
  • Evaluated case-by-case

Quick Explosion Proof Light Classification Example:

Paint Spray Booth → Class I (paint solvents) → Division 1 (always present during operation) → Group D (gasoline-based solvents) = This is an instance of explosion proof light classification: Class I, Division 1, Group D

Key Takeaway: Only UL844-certified fixtures, which are intended for use in hazardous environments as specified by the classification, meet North American safety standards. Never substitute vapor-tight or standard industrial lighting in classified hazardous locations.

Common Explosion Proof Lighting Classifications by Environment

Where can explosion proof lights be used and what class/division applies to each hazardous environment? Our Product Specialists have compiled this reference chart based on typical classifications for common industrial applications.

There is a wide range and variety of explosion proof lighting options available, offering different lumen options and fixture configurations to suit the needs of various industries and applications.

• It is important to note that these are typical classifications only.
• Each facility requires individual assessment by qualified professionals to determine exact hazardous area boundaries and appropriate fixture requirements.
• Speak to a Product Specialist at LED Lighting Supply for a custom lighting plan recommendation, ensuring optimal safety and energy efficiency in your environment.
• Explosion proof lighting is crucial for safely illuminating areas containing flammable materials, as it helps minimize the risk of ignition in hazardous environments.

Common Hazardous Location Classifications by Industry

Reference guide for typical explosion proof lighting requirements

Petroleum Refineries

• Class I, Division 1 & 2 Group D
• Gasoline vapors, petroleum products

Chemical Processing Plants

• Class I, Division 1 & 2 Group C, D
• Ethylene, acetylene, various chemicals

Paint Spray Booths

• Class I, Division 1 Group D
• Paint solvents, volatile organic compounds

Grain Storage/Processing

• Class II, Division 1 & 2 Group G
• Agricultural dust, grain particles

Coal Processing Facilities

• Class II, Division 1 & 2 Group F
• Coal dust, carbonaceous materials

Aircraft Hangars

• Class I, Division 2 Group D
• Aviation fuel vapors

Gasoline Dispensing Areas

• Class I, Division 1 & 2 Group D
• Gasoline vapors

Underground Coal Mines

• Class I & II, Division 1 Group C, F
• Methane gas, coal dust

Flour Mills

• Class II, Division 1 & 2 Group G
• Flour dust, grain particles

Wood Processing Plants

• Class II, Division 2 Group G
• Wood dust, sawdust

Textile Manufacturing

• Class III, Division 1 & 2 No Groups
• Cotton fibers, synthetic materials

Wastewater Treatment

• Class I, Division 2 Group D
• Methane, hydrogen sulfide

Distilleries

• Class I, Division 1 & 2 Group D
• Alcohol vapors, ethanol

Metal Processing

• Class II, Division 2 Group E
• Metal dust, conductive particles

Pharmaceutical Manufacturing

• Class I, Division 2 Group D
• Solvent vapors, chemical processes

Important: These are typical classifications only. Each facility requires individual assessment by qualified professionals to determine exact hazardous area boundaries and appropriate fixture requirements.

Our customer's paint booth converted over to our 50 Watt Round Explosion Proof LED Light | 7000 Lumens explosion proof fixtures

LED Lighting Supply's Explosion Proof Lighting Advantages

Energy Efficiency & Durability

Our explosion proof LED fixtures are highly efficient and consume much less energy than traditional lighting, delivering 50-75% energy reduction compared to traditional HID lighting. 100,000+ hour lifespans eliminate frequent bulb and ballast replacements, reducing maintenance costs and minimizing personnel exposure in hazardous areas. Our explosion proof fixtures are engineered to withstand extreme hazardous location conditions, including:

• High temperature variations
• Moisture and corrosive atmospheres
• Vibration and impact exposure
• Flying debris and harsh chemicals
• LEDs generate less heat, which enhances safety and performance in hazardous environments

60W LED vs 250W Metal Halide Replacement (with ballast)

Based on 12 hours/day, 365 days/year at $0.13/kWh

Metal Halide (288W)

Annual: $163.70 | 5-Year Cost: $818.51 | 5-Year Savings: –

LED UFO Fixture (60W)

Annual: $34.16 | 5-Year Cost: $170.82 | 5-Year Savings: $12953.85

Single Fixture Annual Savings: $129.54 | 20 Fixture Annual Savings: $2591 | ROI Timeline: Under 39 months

Energy Reduction: 79% | 5-Year ROI: 3021% | Lamp Life: 50,000+ (LED) vs 15,000 (MH)

150W LED vs 400W Metal Halide Replacement (with ballast)

Based on 12 hours/day, 365 days/year at $0.13/kWh

Metal Halide (460W)

Annual: $261.92 | 5-Year Cost: $1309.62 | 5-Year Savings: –

LED UFO Fixture (150W)

Annual: $85.41 | 5-Year Cost: $427.05 | 5-Year Savings: $17651.40

Single Fixture Annual Savings: $176.51 | 20 Fixture Annual Savings: $3530 | ROI Timeline: Under 39 months

Energy Reduction: 67% | 5-Year ROI: 3030% | Lamp Life: 50,000+ (LED) vs 15,000 (MH)

Our 40 Watt Explosion Proof Jelly Jar LED Light | 5200 Lumens were installed to replace old halogen jelly jar lights.

Superior Safety Performance

• UL tested and certified to meet stringent requirements in explosive atmospheres
• Instant-on performance eliminates warm-up delays
• Cool-running operation reduces surface temperatures compared to traditional metal halide alternatives

How to Select the Right Explosion Proof Lighting Solution for Your Project

The ideal option is to consult an experienced lighting professional who understands both safety requirements and application-specific needs. It is crucial to select fixtures that provide proper illumination in hazardous environments to ensure safety and durability.

Our Proven Selection Process

Site Assessment and Classification Verification

• Confirm hazardous area classifications
• Identify environmental conditions
• Evaluate mounting requirements

Lighting Design and Layout Planning

• Calculate proper fixture spacing
• Determine appropriate lumen outputs
• Select optimal color temperatures (typically 5000K for industrial applications)

Compliance and Installation Planning

• Verify UL certification requirements; this means the fixtures meet the necessary safety standards for hazardous environments.
• Plan conduit and junction box specifications

Quick Reference: Division 1 fixtures can substitute for Division 2 applications within the same class and group, but never use lower-rated fixtures in higher-classification areas.

How to Install Explosion-Proof Lights

Always use qualified electricians. Explosion proof installations require certified electricians. All components (conduit, junction boxes, switches) must carry appropriate hazardous location ratings.

Follow NEC Article 500-505 Guidelines

• Use explosion-rated conduit systems
• Install proper grounding and bonding
• Maintain required seal-off distances
• Document all installation specifications

Avoid These Common Installation Mistakes:

• Using standard electrical whips or cords
• Mixing rated and non-rated components
• Improper seal-off installation
• Inadequate grounding systems

Understanding Global Explosion Proof Standards

North American Standards (NEC/CEC)

UL844 governs explosion proof lighting in the United States and Canada, using the Division-based classification system outlined above.

International Standards (ATEX/IECEx)

This zoning system defines the frequency and duration of the presence of explosive atmospheres, which are created when combustible dust or gases are present in the air, and dictates the type of explosion-proof protection required for lighting and other electrical equipment.

Gas Environments:

European and international markets use Zone-based classifications.

• Zone 0: Continuous hazardous atmosphere (≥1000 hours/year)
  • Equipment must offer "Ex ia" or "Ex ma" protection - capable of operating safely even during fault conditions.
• Zone 1: Likely during normal operation (10-1000 hours/year)
  • Equipment should have protection like "Ex d" (flameproof) or "Ex e" (increased safety) - robust under standard operation.
• Zone 2: Unlikely during normal operation (≤10 hours/year)
  • Equipment may use "Ex n" (non-sparking) or simplified flameproof enclosures for rare or short-lived hazardous events.

Types of Hazardous Substances

The classification also considers the type of hazardous substance:

• Gas Environments - Zones 0, 1, 2
• Dust Environments - Zones 20, 21, 22 - (similar principles, but apply to combustible dust atmospheres)

Zone 20 / 21 / 22 followed similar logic:

• Zone 20 - dust present continuously or for long periods
• Zone 21 - dust is likely during normal operation
• Zone 22 - dust unlikely but possible under abnormal conditions

Completed Industrial Hazardous Location Lighting Projects using LED Lighting Supply LED Explosion Proof Lights

Frequently Asked Questions About Explosion Proof Lighting

Are All LED Lights Explosion Proof?

No, only LED fixtures certified under UL844 standards qualify as explosion-proof. Standard LED lights lack the reinforced housings and flame path technology required for hazardous locations. Never confuse vapor-tight with explosion-proof—they serve completely different safety functions and cannot be substituted.

Can I Use Vapor-Tight Fixtures Instead of Explosion Proof Lights?

Absolutely not. Vapor-tight lighting only seals out environmental contaminants but cannot contain internal explosions or arcing. Only UL844-certified fixtures provide the flame path containment and reinforced construction required for classified hazardous locations.

Do Explosion Proof Fixtures Require Specialized Maintenance?

Minimal maintenance is required with our UL-certified LED fixtures. Periodic visual inspections and housekeeping maintain optimal performance. The sealed construction and 100,000+ hour LED lifespan eliminate frequent lamp changes that create safety risks in hazardous environments.

What is Class 1 Division 1 Lighting?

Class 1 Division 1 fixtures operate safely where ignitable gases or vapors are continuously present during normal operations. These environments include petroleum refineries, chemical processing areas, and fuel storage facilities where explosive atmospheres exist regularly.

What is Class 1 Division 2 Lighting?

Class 1 Division 2 fixtures handle locations where ignitable gases appear only during abnormal conditions. Examples include pump rooms, compressor stations, or areas adjacent to Division 1 zones where gases might occasionally escape from sealed systems during maintenance.

What is Class 2 Division 1 Lighting?

Class 2 Division 1 fixtures operate where combustible dust or fibers are continuously present in sufficient quantities to create explosive mixtures. Grain elevators, flour mills, and sawdust production areas require this level of protection.

What is Class 2 Division 2 Lighting?

Class 2 Division 2 fixtures work in areas where combustible dust accumulates only occasionally or is normally confined within closed systems. These include adjacent areas to dust processing zones or locations where dust appears only during equipment malfunctions.

Can You Substitute a Class 1 Fixture for Classes 2 or 3?

No, different hazardous material classes require specifically certified fixtures. Gas-rated fixtures lack the dust-tight sealing needed for particulate environments, while dust fixtures may not contain gas explosions properly.

Can You Use a Division 1 Fixture of a Class in a Division 2 Area of the Same Class?

Yes, provided both carry identical group certifications. A C1D1 Group C fixture can substitute in C1D2 Group C areas since Division 1 provides higher protection levels than Division 2 requires.

Is Replacing Metal Halide and Fluorescent Explosion Proof Lights with LED Recommended?

LED retrofits deliver 60-75% energy savings with dramatically reduced heat generation. Our fixtures operate at 120°F surface temperatures versus 400°F+ for metal halide, reducing ignition risks while providing 100,000+ hour lifespans and eliminating hazardous lamp changes.

Do You Offer Explosion Proof Motion Sensors and Photocells?

Yes, we provide UL844-certified motion sensors and photocells designed specifically for hazardous locations. Our junction box sensors control multiple fixtures while NPT-mounted accessories integrate directly with individual fixtures. Find complete options in our Accessory Section.

What's the Best Way to Install LED Explosion Proof Lighting?

Always use electricians certified in hazardous location installations. Every component—conduits, junction boxes, switches—must carry matching hazardous location ratings. Our fixtures connect through NPT threaded entries rather than whips since all wiring methods require explosion-proof certification in classified areas.

Why Choose LED Lighting Supply for Your Explosion Proof Lighting Project

Our extensive experience in hazardous location lighting ensures your project meets all safety requirements while delivering optimal performance and energy efficiency.

Our Consultative Approach Includes:

• Free lighting layout design and photometric analysis
• Specification verification for your exact application requirements
• Technical support throughout installation and commissioning
• Ongoing customer service for maintenance and expansion needs

Ready to Improve Safety and Efficiency in Your Hazardous Location?

Our Product Specialists understand the complexities of explosion proof lighting selection and can ensure you receive the proper solution for your specific environment.

Technical Resources and Standards References

Regulatory Standards & Professional Organizations:

• UL - Underwriters Laboratories: The UL Standard 844 covers luminaires for use in hazardous locations in the USA and Canada.
• IEC - International Electrotechnical Commission: International standards organization including the IECEx system.
• NFPA - National Fire Protection Association: The NFPA publishes the National Electrical Code (NEC) - USA. It includes installation guidelines for electrical equipment in hazardous locations.
• CSA - Canadian Standards Association: Canadian Standard.
• ATEX - Atmospheric Explosive: European Union Standard