Practical guide to explosion protection: basic principles and practical tips

Explosion protection is a central component of occupational safety in surface finishing. Technical measures, regular inspections and clear documentation ensure safe, efficient and compliant work.

Explosion protection is an indispensable part of occupational safety, especially in surface finishing companies that process paint, powder and flock. According to the German Ordinance on Industrial Safety and Health (BetrSichV), these systems are considered to require monitoring, as they have an increased hazard potential due to the processing of flammable coating materials, sometimes in combination with electrostatic application. Since the amendment of the BetrSichV in 2015, employers have been obliged to have the safe condition of such systems checked regularly. It must be ensured that the equipment and the associated processes comply with the applicable safety standards.

Occupational safety follows a clear hierarchy of measures: Technical solutions have top priority, followed by organizational measures and finally personal protective measures. This sequence is also anchored in the Hazardous Substances Ordinance (GefStoffV). The ordinance first requires the substitution of explosive substances with non-explosive materials. Where this is not possible, measures should be taken to prevent or at least minimize the formation of explosive atmospheres. If this is also not sufficient, protective measures are required to prevent ignition or to limit the consequences of explosions through design measures. Areas in which explosive atmospheres may occur must be clearly marked and safeguarded.

Regular inspections: A key to safety

A central aspect of explosion protection is the regular inspection of systems that require monitoring. These inspections are regulated in Annex 2, Section 3 of the BetrSichV. Depending on the type of system and its use, inspections must be carried out at different intervals. Ventilation systems and gas warning systems used for explosion protection, for example, are inspected annually, while devices and protective equipment generally have to be inspected every three years. In addition, the BetrSichV stipulates that the entire explosion protection concept must be comprehensively inspected every six years at the latest.

These inspections may only be carried out by qualified persons or approved inspection bodies. During these inspections, the completeness of the technical documentation, the records of previous inspections and the effectiveness of the protective measures are assessed, among other things. Important guidelines and standards for carrying out these inspections can be found in documents such as DGUV-I 209-052, VDMA standard sheet 24365 or the Technical Rules for Operational Safety (TRBS) 1201.

Trained personnel is key for explosion protection

Another key component of explosion protection is the qualification and training of employees. In accordance with Section 12 BetrSichV, employers are obliged to instruct their employees before commissioning a system for the first time and at least once a year. These instructions must cover the specific hazards, the operating instructions and the measures required in the event of malfunctions or accidents. Written documentation of the instructions is essential, as it serves as proof in the event of damage and helps to minimize legal and financial consequences.

Changing plants: effects on explosion protection

Systems in the surface technology sector are often used for decades. During this time, technical changes, changes in coating materials or adjustments to working methods frequently occur. These changes can affect the original safety concept of the plant. Frequent hazards arise, for example, from the use of new, solvent-based coating materials, exceeding approved material quantities or the integration of application systems with electrostatics.

Further risks arise from the installation of additional equipment, switching from manual to automated processes or improper component changes. Deviations from the original condition or from the intended use of the system must therefore be carefully checked for additional hazards. Only through these assessments can suitable measures be taken to maintain or restore the safety level of the system.

Inventory protection and regular inspection

At the time of commissioning, systems that meet the technical requirements and safety standards are considered safe and enjoy grandfathering. As long as there are no new findings about additional hazards, this status is maintained. Nevertheless, it is essential in practice to regularly review the status quo. The recommendation on operational safety (EmpfBS) 1114 provides clear guidelines for this: Risk assessments must be revised if work equipment or processes change, technical deficits are identified, accidents or near misses occur or new regulations come into force.

The results of these risk assessments form the basis for updating or creating the explosion protection document, as described in DGUV Information 213-106. This document must set out all relevant measures and tests in detail and always be kept up to date.

The importance of comprehensive documentation

Thorough documentation is crucial to avoid legal and financial risks. Employers must ensure that all relevant documentation is always complete and up to date. In particular, this includes risk assessments for processes and work areas, explosion protection documents, operating instructions for hazardous work areas, hazardous area markings and proof that inspections and annual training have been carried out. Missing or incomplete documentation can have significant consequences in the event of damage, including the loss of insurance benefits or claims for damages. Through consistent documentation and compliance with the prescribed measures, operators can operate their systems safely and minimize legal risks at the same time.

Conclusion: Safety through consistent implementation

Explosion protection in companies requires a holistic approach that takes into account technical measures, organizational processes and the human factor. Only by regularly inspecting systems, training employees and fully documenting all measures can employers create a safe working environment in the long term and comply with legal requirements. This not only guarantees the safety of employees, but also ensures the reliable and economical operation of the systems.

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