Ultimate Guide to Explosion Proof CCTV Cameras

High-risk industries such as oil and gas, mining, and chemical plants place safety above all else. These environments often contain flammable gases, dust, or volatile chemicals that can trigger explosions if not carefully monitored.

One vital safety device used in these areas is the Explosion Proof CCTV Camera. Unlike standard cameras, these are built to operate without sparking or igniting hazardous substances. They monitor operations, help detect abnormalities, and play a key role in preventing accidents.

This guide explores Explosion Proof Cameras, ATEX-certified models, and Explosion Protected Cameras, how they work, and why they are essential for workplace safety.

According to the International Labour Organization (ILO), over 340 million occupational accidents occur annually, with hazardous industries accounting for a significant share. Oil and gas sites see about 1.6 injuries per 100 workers according to the U.S. Bureau of Labor Statistics, showing the clear need for strong safety tools.

ATEX-certified cameras designed for Zone 1 and 2 (gases) and Zone 21 and 22 (dust) help meet strict EU safety regulations under Directive 2014/34/EU. These cameras are built with flameproof or pressurised enclosures that prevent internal sparks from igniting the surrounding atmosphere. By enabling real-time remote monitoring, they reduce downtime, support incident response, and enhance safety compliance across high-risk sites.

What Are Explosion Proof CCTV Cameras?

An Explosion Proof CCTV Camera is a special type of security camera. It's designed to work in places where there is a risk of fire or explosion. These cameras are placed inside strong, sealed housings that stop sparks or heat from escaping and causing danger.

The term “explosion proof” means the camera won’t trigger an explosion, even if something goes wrong inside it.

These cameras are often ATEX certified, which means they meet strict European safety standards. Many also carry the IECEx certification, used internationally.

Main Features:

1. Strong metal housings: These are built from stainless steel or aluminium alloys to handle tough conditions. They protect the camera from impacts, high pressure, and exposure to harsh chemicals, making them ideal for heavy-duty industrial use.

2. Resistant to heat, dust, and corrosion: Explosion proof cameras can operate in extreme temperatures and dirty environments. They keep working even in places with chemical fumes, salt air, or abrasive dust, ensuring clear images in every condition.

3. Sealed to keep gases or sparks in: The sealed enclosures prevent any internal sparks or heat from escaping into the air. Even if a fault occurs inside the camera, it won’t ignite nearby gases or particles, helping to avoid serious accidents.

4. Suitable for hazardous areas like Zone 1 or Zone 2: Zone 1 means explosive gases are likely during normal operations; Zone 2 means they are less frequent. These cameras are specially rated for such zones, offering constant, safe monitoring without the risk of ignition.
   
   Always choose ATEX/IECEx certified cameras; safety and compliance come before cost. 
   

Types of Explosion Proof CCTV Cameras

Selecting the right explosion proof CCTV camera is essential for safety in hazardous environments. From wide-area monitoring to confined-space surveillance, different camera types serve different needs. Below is a streamlined overview of key options:

1. Explosion Proof Fixed Camera

A non-movable camera designed to monitor a specific zone. It offers reliable, continuous coverage.

• Best for: Entry points, storage areas

• Features: ATEX explosion proof housing, IR vision, weather resistance

• Use: Effective as a hazardous area camera in static locations
  
  

2. Explosion Proof PTZ Camera

PTZ (Pan-Tilt-Zoom) cameras allow remote directional control and zoom, ideal for covering wide areas.

• Best for: Oil rigs, refineries, large outdoor sites

• Features: 360° rotation, optical zoom, real-time tracking

• Use: Suitable for dynamic zones requiring live monitoring

3. Explosion Proof Dome Camera

A compact, vandal-resistant camera for discreet surveillance, often indoors or in sheltered areas.

• Best for: Control rooms, corridors, chemical labs

• Features: Dome enclosure, IR, fixed or varifocal lens

• Use: Reliable explosion proof security camera in tight spaces
  
  

4. Explosion Proof Mini IR Camera

A small camera built for installation in confined or narrow spaces, without compromising image quality.

• Best for: Inside machinery, small enclosures

• Features: Compact design, built-in infrared, durable casing

• Use: Common in mining and manufacturing zones

5. Explosion Proof ZOOM IR Camera

Combines long-range IR vision with motorised zoom for monitoring distant areas in low light.

• Best for: Pipelines, perimeter fences, offshore sites

• Features: Zoom lens, extended IR range, motion detection

• Use: Ideal for expansive hazardous locations

6. Explosion Proof Wireless Camera

Designed for areas where cabling is impractical or unsafe. Offers flexibility without compromising safety.

• Best for: Temporary zones, mobile equipment

• Features: Wireless connection, remote access, battery support

Use: A practical explosion proof surveillance camera for remote sites

Choosing the Right Solution

Select a camera that fits your site's hazard zone and complies with ATEX standards. SharpEagle Technology offers explosion proof cameras built for safety, clarity, and performance in hazardous environments.

How Explosion Proof Cameras Work

An Explosion Proof Surveillance Camera works by keeping its electrical parts completely sealed inside a tough case. If something inside causes a spark, it can’t escape and ignite anything outside.

The body of the camera is often made of stainless steel or aluminium. These materials can handle heat, pressure, and harsh conditions.

These cameras also come with:

Heat sinks to stop overheating

Heat sinks help pull heat away from the camera’s internal parts, keeping it cool during long use. This is important in hot or enclosed spaces where heat builds up quickly. By preventing overheating, the camera lasts longer and keeps working safely without risk of failure or fire.

Tightly sealed cable entries to avoid leaks

Cables enter the camera through specially designed seals that block out dust, moisture, and gases. This keeps the inside safe from anything that could cause a short circuit or spark. It also helps maintain the explosion proof rating by ensuring nothing leaks in or out of the housing.

Special sensors for detecting movement, gas, or fire

Some explosion proof cameras include smart sensors to spot motion, gas leaks, or signs of fire. These features allow quick response to danger, helping protect workers and equipment. The sensors send alerts in real time, supporting early action and reducing the risk of major incidents in hazardous zones.

This makes them perfect for safe monitoring in explosive environments.

Why Choose Explosion Proof CCTV Cameras for Hazardous Areas?

A simple spark can lead to a huge accident in dangerous industries. That’s why Hazardous Area Cameras are so important. They provide live video, help you spot risks early, and improve emergency responses. Many Explosion proof IP cameras support remote access, allowing real-time monitoring of risky zones from a safe control room or off-site location.

Here’s how Explosion Proof CCTV helps:

• Keeps workers safe

• Prevents explosions by stopping sparks

• Allows remote monitoring of risky areas

• Helps follow safety laws and rules

They’re used in:

• Oil refineries

• Offshore platforms

• Gas plants

• Chemical factories

• Power stations

ATEX Explosion Proof Cameras and Certifications

ATEX Explosion Proof Cameras meet European laws for equipment used in explosive environments. Getting an ATEX certification means the camera passed tough tests and is safe to use in places with flammable gases or dust.

There are two ATEX directives:

• ATEX 114: For equipment like CCTV cameras

• ATEX 153: For protecting workers in explosive areas

Without ATEX, you can’t be sure the camera is safe. An ATEX-certified camera is tested to work without creating danger.

When selecting equipment for explosive zones, always choose models that are certified under ATEX IECEx standards to ensure global compliance and safety. Some cameras also have the IECEx mark, which is like ATEX but used worldwide.

Understanding Hazardous Area Classifications

Hazardous areas are grouped into zones or divisions based on how likely an explosion is to happen.

Gas Zones:

• Zone 0: Explosive gas is present all the time or for long periods, making it the most dangerous gas zone.

• Zone 1: Explosive gas is likely to appear during normal operations or maintenance work, so strong safety measures are needed.

• Zone 2: Explosive gas is not usually present, but it may appear briefly or by accident under abnormal conditions.

Dust Zones:

• Zone 20: Combustible dust is always in the air, creating a constant explosion risk in enclosed or powder-heavy environments.

• Zone 21: Dust is often found during normal operations, so equipment must be safe for regular exposure to combustible particles.

• Zone 22: Dust is rarely present and usually only in case of faults or unexpected leaks, but risks still exist.

In the US, they use Division 1 and Division 2 instead.

Explosion Proof Cameras are made to match these zones. If you put the wrong camera in the wrong zone, you risk fire, injury, and fines.

Benefits of Explosion Proof Cameras

Here’s why these cameras are a smart choice for your business:

They prevent fires and explosions

Explosion proof cameras are built to contain sparks or heat, stopping them from escaping into the air. This prevents dangerous reactions with gases or dust in the environment. By doing so, they help reduce the chance of fires or explosions in high-risk areas like chemical plants or refineries.

They protect workers and property

With constant video monitoring, these cameras spot problems early, such as gas leaks or overheating equipment. Early warnings mean staff can take action before things get worse. This protects not only employees from harm but also valuable machinery, buildings, and materials from serious damage or total loss.

They help meet safety rules

Explosion proof cameras often come with ATEX or IECEx certification, meaning they meet strict international safety standards. Using certified equipment helps businesses stay compliant with laws and industry rules, avoiding fines or shutdowns. It also builds trust during safety inspections and improves a company's overall risk management.

They allow remote viewing of dangerous areas

Many explosion proof cameras can be accessed remotely through secure systems. This means staff can safely monitor hazardous zones from a distance, without entering risky areas. It improves response times, supports decision-making in emergencies, and keeps more workers out of harm’s way during daily operations.

They reduce downtime and accidents

Explosion Proof Security Cameras are designed to deliver clear, uninterrupted video even in the most volatile industrial zones, helping prevent costly incidents. Early detection of issues like equipment failure, temperature spikes, or gas leaks means repairs can happen before major problems arise. This cuts down on unexpected shutdowns and helps keep production running smoothly. Fewer accidents also mean fewer delays, better worker safety, and lower costs for emergency repairs or claims.

Whether it’s gas leaks, hot machinery, or flammable dust, these cameras help spot danger before it gets out of hand.

Choosing the Right Explosion Proof CCTV Camera for Your Business

There are many models available. To choose the right one, consider:

What to Check:

ATEX or IECEx certified: Always check for safety marks

These certifications prove the camera is safe for explosive environments. ATEX is for Europe, IECEx is international. Always look for these labels, they mean the camera has passed strict safety tests and can legally be used in areas with flammable gas, vapour, or dust.

Choosing the right CCTV Camera for a hazardous site means looking beyond image quality; safety certifications, material strength, and environmental resistance are just as vital.

Material: Stainless steel is best for harsh weather or chemicals

Stainless steel is strong, rust-resistant, and can handle rough conditions. It’s ideal for places with salt air, heavy rain, heat, or corrosive chemicals. Using a camera made of tough material ensures longer life and less maintenance, even in extreme industrial or outdoor environments.

IP rating: Choose waterproof or dustproof models

The IP (Ingress Protection) rating tells you how well a camera can resist water and dust. For example, IP66 or IP67 cameras are good for outdoor or dusty places. A high IP rating keeps the camera safe, even in storms or dirty factory zones.

Image quality: Go for high resolution and night vision

Cameras with HD or 4K resolution give clearer video, making it easier to spot problems. Night vision is essential for 24/7 monitoring in low-light areas. Together, these features help capture vital details like gas leaks, trespassers, or equipment faults at any time of day.

Operating temperature: Pick one that works in heat or cold

Check if the camera can handle the temperatures in your area. Some models work in freezing cold or extreme heat without shutting down. This is key for places like deserts, cold storage, or hot engine rooms, where normal cameras might fail.

Installation space: Some cameras need special mounts or brackets

Explosion proof cameras can be large and heavy. Some need special brackets, poles, or wall mounts for safe and stable setup. Make sure the space allows proper fitting, angle adjustment, and access for cleaning or maintenance. This ensures the camera works effectively without being in the way.

If you’re not sure, speak to a trusted provider like SharpEagle Technology for advice.

Match the camera to the exact zone (e.g., Zone 1, Zone 21); wrong placement risks safety and legality.

Common Applications of Explosion Proof CCTV Cameras

These cameras are used across many industries, especially where the air might contain flammable gases or dust.

Industries That Use Them:

1. Oil and gas plants: These sites often have flammable gases under high pressure. Explosion proof cameras help monitor pipelines, pumps, and tanks to spot leaks or overheating early, helping prevent fires, explosions, and costly downtime.
   
   

2. Chemical factories: Chemicals can release harmful fumes or cause reactions. Cameras in explosion proof housings keep watch over mixing, bottling, and storage areas, helping staff respond quickly if anything goes wrong, without risking ignition from standard equipment.
   
   

3. Mining operations: Dust, gas pockets, and machinery make mines very risky. These cameras give clear views deep underground or in open pits, improving worker safety and helping detect equipment failures or dangerous gas build-ups before they cause harm.
   
   

4. Power plants: Power plants use flammable fuels or high heat. Explosion proof cameras monitor boilers, generators, and control rooms to ensure smooth operations and catch problems like overheating or leaks before they become major hazards.
   
   

5. Paint shops: Paint fumes are highly flammable. These cameras safely track spray booths and mixing rooms, reducing the risk of explosion from electrical sparks. They also help maintain quality by providing clear footage of painting operations.
   
   

6. Fuel stations: Fuel vapours can ignite easily. Cameras with explosion proof design allow 24/7 monitoring of pumps, tanks, and loading areas. They help detect spills or suspicious activity quickly, ensuring safety for both staff and customers.

Real life Example:

At a chemical plant in Saudi Arabia, ATEX-certified explosion protected cameras were installed in all hazardous zones. They provided round-the-clock video coverage, helping detect gas leaks, overheating valves, and blocked pipelines. This early warning system reduced serious accidents, improved emergency response times, and cut maintenance costs significantly, making operations safer and more efficient.

Installation and Maintenance of Explosion Proof CCTV Cameras

Installing these cameras the right way is key to keeping them safe and working well.

Installation Tips:

• Hire trained professionals: Certified experts understand explosion proof standards and know how to install safely in hazardous zones without causing risks.

• Seal all cables properly: Well-sealed cables stop dust, gas, or moisture from entering the housing, keeping the camera explosion proof and fully protected.

• Keep the camera grounded to stop static: Proper grounding prevents static build-up, which could create sparks, especially important in areas with flammable gases or dust.

Maintenance Tips:

• Clean the lens and housing regularly: Dust or dirt can block visibility. Regular cleaning keeps the camera clear and ensures high-quality footage at all times.

• Check for rust or damage: Corrosion or cracks can weaken protection. Regular checks help spot issues early and keep the camera safe to use.

• Test the camera’s video feed often: Frequent testing ensures the video is clear and uninterrupted, so issues can be fixed before they affect safety.

• Update software if needed: Software updates improve performance, fix bugs, and add features, helping the system run smoothly and stay secure.

Proper care ensures long life and top performance.

Conclusion: 

Explosion Proof CCTV Cameras are essential for any business operating in hazardous environments. They do far more than just record footage; they save lives, prevent accidents, and help meet strict safety regulations. These cameras are a proactive step towards building a safer, more reliable workplace.

With the right model, your operations become not only safer but also more efficient and compliant. The ability to monitor danger zones in real time helps reduce downtime, catch early signs of trouble, and support quicker emergency response.

If you work in oil and gas, chemicals, mining, or any explosive-prone field, investing in Explosion Proof Camera solutions is no longer optional; it’s a must. Trusted providers like SharpEagle Technology offer certified, high-performance systems designed for tough industrial settings, giving you peace of mind, smarter surveillance, and stronger protection where it matters most.

Frequently Asked Questions

Q1: What makes a device explosion proof?

It has a strong, sealed housing designed to contain internal sparks or heat, preventing ignition of flammable gases or dust outside. An Explosion Proof CCTV Camera is built to operate safely in hazardous areas, where standard equipment could pose a serious fire or explosion risk.

Q2: Why are Explosion Proof Cameras important for industrial environments?

They provide continuous monitoring in high-risk zones, helping detect gas leaks, overheating, or system faults early. Explosion Proof Cameras are vital in environments where flammable materials are present, as they reduce accident risks and improve overall workplace safety for both personnel and equipment.

Q3: Can ATEX Cameras withstand subzero temperatures?

Yes, many ATEX-certified camera models are designed to perform reliably in freezing temperatures as well as extreme heat. This makes them suitable for outdoor use, cold storage, and remote locations, ensuring safety monitoring continues even in harsh weather or climate conditions.

 Q4: How do Explosion Proof CCTV Cameras prevent explosions?

These cameras have specially engineered enclosures that trap any internal sparks or faults. This prevents contact with external gases or dust. An Explosion protected camera doesn’t allow ignition to spread outside, making it safe for use in ATEX Zones 1, 2, 21, and 22.

Q5: How do I choose the right Explosion Proof Camera for my business?

Start by selecting an ATEX Rated camera that suits your zone classification. Consider the operating temperature range, resolution, lens type, and mounting needs. Make sure it matches your environment and complies with safety regulations to ensure reliable performance in hazardous industrial areas.

Get Safer, Smarter Surveillance – Contact SharpEagle Now

Protect your people, property, and operations with trusted ATEX-certified Explosion Proof CCTV solutions.

Get in touch with SharpEagle Technology today to explore expert installation, tailored advice, and advanced camera systems built for the most hazardous environments. Your safer workplace starts here.