LED Explosion Proof Lights for Hazardous Locations

What Are Explosion Proof Lights and Why Your Facility Needs Them

Explosion proof light fixtures, commonly referred to as hazardous area lighting, are engineered safety systems designed to contain and prevent explosions in hazardous industrial environments where flammable gases, liquids, or combustible dust create ignition 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 LED lights also eliminate 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 specifically engineered 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 environments

The Occupational Safety and Health Administration (OSHA) provides comprehensive guidance on electrical safety in hazardous locations, emphasizing that proper classification and equipment selection are critical to preventing workplace explosions and protecting workers. OSHA's standards for hazardous locations detail the requirements for electrical installations in areas where flammable gases, vapors, liquids, or combustible dusts may be present.

Applications & Industries Where Explosion-Proof Lighting Is Required

Chemical Processing & Storage Facilities

Industrial Manufacturing

Energy & Utilities

Explosion proof lighting is used in a variety of settings, including laboratories, refineries, fabrication workshops and food and beverage facilities, and other locations 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. They experienced a dramatic improvement in light quality when they converted over to LED

Case Study: Conversion of existing lighting to LED Lighting Supply Class 1 Division 2 Fixtures in Holbrook, AZ

After: 200 Watt Square Explosion Proof LED Light | 28000 Lumens	After: 200 Watt Square Explosion Proof LED Light | 28000 Lumens

Lighting Plan We Created for the Customer

Lighting Plan	Heat Map

Explosion Proof Lighting Installation Plan Metrics

• Mounting height: 20 ft
• Fixture Used: MLLG-E-LED-EXPLA-200-50-[V]-C1D2: 200 Watt Square Explosion Proof LED Light | 28000 Lumens | Class 1 Div 2 | Class 2 Div 2 | 5000K | 100V-277V or 277V-480V
• FC achieved: 62.80 FC average
• Uniformity (Avg/Min): 1.85

Case Study: Conversion of existing paint booth metal halide explosion proof lighting to LED Lighting Supply Class 1 Division 1 Fixtures in Chicago, IL

Before: 100 Watt Round Explosion Proof Metal Halide Light	After: 50 Watt Round Explosion Proof LED Light | 7000 Lumens

Lighting Plan We Created for the Customer

Lighting Plan	Heat Map

Explosion Proof Lighting Installation Plan Metrics

• Mounting height: 10 ft
• Fixture Used: LLS-EXPLC-50-5-C1D1: 50 Watt Round Explosion Proof LED Light | 7000 Lumens | Class 1 Div 1 | 5000K | 100-277V
• FC achieved: 53.54 FC average
• Uniformity (Avg/Min): 1.59

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.

The National Fire Protection Association (NFPA) establishes the foundational standards for hazardous location classification through NFPA 70, the National Electrical Code (NEC). The NEC provides comprehensive guidelines for determining proper electrical equipment ratings based on the type and concentration of hazardous materials present in industrial environments.

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)

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

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

Common Hazardous Location Classifications by Industry

Reference guide for typical explosion-proof lighting requirements subject to site conditions

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

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 depending on model 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

What are the Cost Savings and ROI When You Convert from Metal Halide to LED?

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

Assumptions: Based on 24 hours/day, 365 days/year at $0.16/kWh, 20 fixture(s), and a 15% ballast factor applied to the metal halide wattage (250W lamp + 15% ballast = ~ 288W input).
•  Energy cost and ROI calculations are based on energy savings only and assume an LED fixture cost of $415.00 per fixture.
• Maintenance savings from reduced bulb and ballast replacements are not included in these calculations.

In this example with 20 fixture(s), total LED fixture investment is approximately $8,300.00, and estimated annual energy-only savings are $6,377.28. Simple payback based on energy savings alone is under 16 months. Maintenance savings from eliminating metal halide bulb and ballast replacements provide additional value throughout the fixture's 50,000-hour lifespan, but are not included in this ROI calculation.

The U.S. Department of Energy has extensively documented the energy savings potential of LED lighting in industrial applications, noting that LED technology can reduce energy consumption by 50% or more compared to conventional lighting technologies. The DOE's Solid-State Lighting program demonstrates how LED adoption in industrial settings contributes to significant operational cost reductions and improved workplace safety through better light quality and reduced heat generation.

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

Superior Safety Performance

• UL tested and certified per listed certifications to meet the highest standards 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

Quick Reference: Division 1 fixtures can substitute for Division 2 applications within the same class and group when properly specified, 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.

Explosion Proof Certifications & Compliance

All explosion proof lighting fixtures offered by LED Lighting Supply carry certifications for hazardous location use in accordance with applicable safety standards.

• UL844 certified for Class I, II, and III hazardous locations in North America
• ATEX and IECEx certified options available for international and zone-based applications

Not sure which certification or classification applies to your facility? See our Hazardous Location Lighting Buyer's Guide for a full breakdown of NEC vs ATEX standards, zones, divisions, and substance types.

Common Mistakes and How to Avoid Them

After 15+ years in hazardous location installations, we keep seeing facilities make the same dangerous mistakes with explosion proof lighting. Most problems come from treating these installations like regular industrial jobs without understanding the unique safety requirements.

• Using standard whips or flexible cord instead of rigid conduit. Hazardous location wiring must follow NEC 501 requirements with explosion-rated connectors.
• Mixing certified and non-certified components, thinking it's acceptable. Every single component in the electrical path needs a proper hazardous location rating.
• Installing seal-offs in the wrong locations or skipping them entirely. Check NEC 501.15 for exact requirements on seal-off placement and compound types.
• Assuming Division 2 fixtures work for Division 1 applications because they're almost the same. Division ratings are absolute and non-negotiable.
• Forgetting to torque fixture covers to the manufacturer's specifications. Loose covers compromise the explosion containment and void certifications.
• The conduit runs too long between seal-offs. Maximum distances are specified in code and cannot be exceeded, even by a few feet.
• Failing to properly ground and bond all metallic components. Poor grounding creates static discharge risks in explosive atmospheres.
• Installing fixtures before verifying the actual hazardous area boundaries. What looks like Division 2 might actually be Division 1, depending on ventilation and process conditions.

LED Explosion Proof Lights for Hazardous Locations Frequently Asked Questions

What Types of Hazardous Environments Require Explosion Proof Lighting?

Explosion proof lighting fixtures are required in environments where flammable gases, vapors, liquids, or combustible dust create ignition risks. Common applications include petroleum refineries, chemical processing plants, paint spray booths, grain storage facilities, coal processing plants, power plants, and mining operations. Each environment requires specific UL844-certified fixtures rated for the particular class and division of hazardous materials present.

How Do I Determine What Class and Division Rating My Facility Needs?

Use the three-step NEC classification process: identify hazardous material type (Class I gases/vapors, Class II combustible dust, Class III fibers), determine presence frequency (Division 1 for continuous presence, Division 2 for abnormal conditions only), and select the specific group classification based on your exact materials. For example, a paint spray booth typically requires Class I, Division 1, Group D fixtures due to continuous solvent vapors during operation.

What Is the Difference Between Division 1 and Division 2 Explosion Proof Lights?

Division 1 fixtures are designed for areas where ignitable gases are present continuously or frequently during normal operations, representing high risk environments. Division 2 fixtures are rated for locations where hazardous materials only appear during abnormal conditions or equipment failures, representing moderate risk environments. Division 1 fixtures can be used in Division 2 applications, but never use Division 2 fixtures in Division 1 areas.

How Much Energy Can LED Explosion Proof Lights Save Compared to Metal Halide?

LED explosion proof fixtures deliver 50-75% energy reduction compared to traditional HID lighting. A 60W LED fixture replacing a 250W metal halide system saves $129.54 annually per fixture, while a 150W LED replacing a 400W metal halide saves $176.51 annually. With 100,000+ hour lifespans, LEDs also eliminate frequent bulb replacements in hazardous areas, reducing maintenance costs and personnel exposure risks.

Can Standard Industrial or Vapor-Tight Fixtures Be Used in Hazardous Locations?

Never substitute vapor-tight or standard industrial lighting in classified hazardous locations. Only UL844-certified fixtures meet North American safety standards for explosion proof applications. Standard fixtures can become ignition sources, while hazardous location lights are engineered to contain internal explosions and prevent ignition of surrounding atmospheres. Using non-certified fixtures in hazardous environments violates safety codes and creates serious explosion risks.

What Installation Requirements Apply to Explosion Proof Lighting?

Explosion proof installations require certified electricians and must follow NEC Article 500-505 guidelines. All components including conduit, junction boxes, and switches must carry appropriate hazardous location ratings. Critical requirements include using explosion-rated conduit systems, proper grounding and bonding, maintaining required seal-off distances, and avoiding standard electrical whips or mixing rated and non-rated components.

How Do ATEX/International Zone Classifications Compare to NEC Divisions?

International markets use Zone-based classifications instead of the North American Division system. Zone 0 requires continuous protection (equivalent to Division 1 high-risk), Zone 1 covers likely presence during normal operation, and Zone 2 addresses unlikely presence during normal operation (similar to Division 2). Dust environments use Zones 20, 21, and 22 with similar logic for combustible dust atmospheres rather than gas and vapor hazards.

What Certifications Should I Look for in Explosion Proof LED Fixtures?

Look for UL844 certification for North American installations, which ensures fixtures meet stringent explosion containment requirements. Additional valuable certifications include ETL Listed for safety compliance, DLC Qualified for energy efficiency and utility rebates, and IP65 rating for dust and water resistance. NSF certification is important for food processing applications where explosion proof lighting intersects with sanitary requirements.

Why Choose LED Lighting Supply for Explosion Proof Lighting Projects?

We bring 15+ years of commercial and industrial lighting expertise with 25,000+ completed projects to help facilities achieve UL844-certified safety in demanding environments. Our consultative approach goes beyond product sales to provide technical guidance, detailed energy savings calculations, and complimentary custom lighting plans tailored to your specific hazardous location requirements. This eliminates costly specification errors and ensures optimal fixture placement while maintaining full safety compliance.

How Long Do Explosion Proof LED Fixtures Last Compared to Traditional Options?

Explosion proof LED fixtures provide 100,000+ hour lifespans compared to 15,000 hours for metal halide systems. This extended life eliminates frequent bulb and ballast replacements, reducing maintenance costs and minimizing personnel exposure in hazardous areas. LEDs also generate less heat than traditional HID lighting, enhancing safety performance and reducing surface temperatures in explosive atmospheres.

What Common Mistakes Should Be Avoided When Specifying Explosion Proof Lighting?

Never use lower-rated fixtures in higher-classification areas , such as installing Division 2 fixtures in Division 1 environments. Avoid mixing standard electrical components with explosion proof fixtures, using inadequate seal-off installations, or selecting fixtures without proper UL844 certification. Each facility requires individual assessment by qualified professionals rather than assuming typical classifications apply, as exact hazardous area boundaries vary significantly between installations.