- Consultivo · Process Safety · IFC-Approved
Hazardous Area Classification Consultants for Explosive Atmospheres
Independent hazardous area classification that maps where flammable gas, vapour or dust can occur, and defines exactly what equipment is safe to install there. Zone drawings your regulator and insurer will accept.
What You Get
What a Hazardous Area Classification Delivers
A hazardous area classification turns your process and layout into a clear map of risk, so the right equipment goes in the right place and your compliance is defensible.
Zone Drawings and Maps
Detailed classification drawings, zoning layouts and 3D visualisations aligned to your plant and operations.
Equipment Selection
A clear view of what Ex-rated equipment is safe in each zone, with mismatches on existing kit flagged.
Standards Alignment
Classification to IS 5572, IEC 60079, ATEX and NFPA, so you meet statutory and insurance requirements.
Technical Recommendations
Advice on equipment placement, ventilation and safety signage to close compliance gaps and cut risk.
Why Consultivo
Hazardous Area Classification Consultants Who Get the Zones Right
A minor mistake in zone classification can lead to a major incident. Independence and accuracy are what we bring.
IFC World Bank Group approved
The independence and rigour that development lenders and international insurers expect for high-hazard facilities.
Truly independent
We sell no equipment, software licences or instrumentation, so our classification carries no commercial bias.
Multi-standard practice
IS 5572, IEC 60079, ATEX, NFPA and NEC, matched to your project location and regulator.
Audit-ready drawings
Technically accurate, clearly labelled zone drawings that operational teams and external auditors can both read.
All ignition sources
We assess electrical and non-electrical ignition sources, including hot surfaces, static and friction.
India and 19+ countries
Indian statutory depth combined with international practice, across 2,000+ organisations and 20+ sectors.
Understanding The Study
What Is Hazardous Area Classification?
Hazardous area classification is the process of identifying locations where a risk of fire or explosion exists because flammable gases, vapours, liquids or combustible dusts may be present, and classifying those locations into zones by how often and how long an explosive atmosphere is likely to occur.
The classification is the basis for safe design, equipment selection, maintenance and operation. Its purpose is to prevent ignition sources in hazardous areas, select equipment rated for the zone, protect people and assets, and comply with the applicable standards. The recognised gas reference is IEC 60079-10-1, the area-classification standard.
Classification often follows the qualitative work of our process hazard analysis consultants, and sits within a full process safety management programme.
Full form: Hazardous Area Classification. Systems: Zone (IEC, India, Europe) and Class or Division (North America). Standards: IS 5572, IEC 60079, ATEX, NFPA. Output: zone drawings and an equipment schedule.
The Classification
Hazardous Area Zones 0, 1 and 2
In the Zone system, gas and vapour areas are graded by how often an explosive atmosphere is present. The hour bands below are a common indicative guide.
Zone 0
Explosive atmosphere present continuously or for long periods, an indicative guide of more than 1,000 hours a year.
Zone 1
Explosive atmosphere likely in normal operation, an indicative 10 to 1,000 hours a year.
Zone 2
Explosive atmosphere unlikely in normal operation and short-lived if it occurs, an indicative under 10 hours a year.
Dust: Zones 20, 21, 22
Combustible dust areas use the parallel set, Zone 20, 21 and 22, on the same likelihood logic.
Frameworks
Standards and Systems We Work To
Two systems classify hazardous areas. The Zone system is used across India, Europe and most of the world; the Class and Division system is used in North America. We work in both, matched to your regulator and project location.
Every drawing and design we deliver is aligned with the standard your regulator, lender or insurer expects.
Standards We Work To
- IS 5572 - Indian standard for area classification
- IEC 60079 series - explosive atmospheres, including 60079-10-1
- ATEX - European directive for explosive atmospheres
- NFPA 497 and 499, NEC / NFPA 70 - US codes
- OSHA, HSE and API - referenced best practice
Our Approach
How We Deliver a Hazardous Area Classification Study
A structured six-stage approach - independent, standards-based and built to give you audit-ready outputs.
Scoping and Team
Define the study scope, identify critical process areas and form a joint team with your experts.
Data and Site Assessment
Study plant layout, ventilation and operations, and gather flammability data, incident records and P&IDs.
Hazard Identification
Identify sources of release such as valves, pumps and storage, across normal, abnormal and emergency conditions.
Zone Classification and Mapping
Assign Zone 0, 1 or 2 to each area, based on international best practice and local standards.
Equipment Review
Assess electrical and non-electrical equipment in the zones, flag mismatches and recommend safer options.
Reporting and Roadmap
Deliver classification charts, zoning maps, compliance gaps and a prioritised action plan.
Sectors We Serve
Industries That Rely on Hazardous Area Classification
Any facility that handles flammable gases, vapours or combustible dusts needs hazardous area classification. Our consultants bring sector-specific knowledge to each one.
What You Receive
Deliverables From the Study
Clear, audit-ready outputs you can use for statutory compliance, audits and insurance. Every hazardous area classification comes with a full documentation set.
HAC report
The full classification study, assumptions, results and compliance status.
Zoning layout drawings
Classified areas, zone extents and equipment guidance, audit-ready.
Equipment compliance review
Existing equipment checked against the zone, with mismatches flagged.
Risk control recommendations
A prioritised plan to close gaps, with codes and standards mapping.
Related Process Safety Services
One incident, one audit, one gap can touch every part of a plant. Here is the rest of the Consultivo team working alongside this study.
Process Safety Management
The full hub — PSM, HAZOP, QRA and every process safety study.
Explore PSMProcess Hazard Analysis Consultants
HAZID, HAZOP, What-If and Checklist studies.
Explore PHAQRA Consultant
Consequence modelling and numerical risk for siting and lenders.
Explore QRAElectrical Safety Audit
Independent electrical safety assessment and thermography.
Explore auditIncident Investigation
Root cause analysis for near misses and fire incidents.
Explore investigationSafety Training Courses
Process and electrical safety upskilling for your team.
Explore trainingFAQ
Hazardous Area Classification, Your Questions Answered
What exactly is a hazardous area?
A hazardous area is a location where the atmosphere may contain flammable gases, vapours or dusts in quantities that could cause a fire or explosion. These areas need special safety design and equipment selection, and hazardous area classification is how they are identified and managed.
What are Zones 0, 1 and 2?
The zones grade the level of risk in a gas or vapour area. As an indicative guide, Zone 0 has an explosive atmosphere present continuously or for long periods (over 1,000 hours a year), Zone 1 is likely during normal operation (10 to 1,000 hours a year), and Zone 2 is unlikely and short-lived if it occurs (under 10 hours a year). The zone determines what equipment is suitable.
What is the difference between a Zone system and a Class or Division system?
The Zone system is used across India, Europe and most of the world. The Class and Division system is used in North America. Both classify the same risk in different formats, and Consultivo works with whichever suits your regulatory environment and project location.
Which standards do you follow for hazardous area classification?
We follow global and Indian standards, including IS 5572, the IEC 60079 series, NFPA 497 and NEC / NFPA 70, and the ATEX directive for European projects. We also reference OSHA, HSE and API and industry-specific best practice.
What documents will I receive from the study?
You receive a hazardous area classification report, zoning layout drawings, an equipment compliance review, risk control recommendations, and a mapping of the applicable codes and standards. These documents support audits, statutory compliance and insurance.
Can existing hazardous areas be reclassified?
Yes. If the plant layout, materials handled, ventilation or safety systems change, we can review and reclassify the affected areas. Periodic reviews are also recommended as part of good safety management.
Does HAC include non-electrical equipment?
Yes. Modern practice recognises non-electrical ignition sources such as hot surfaces, static discharge and friction as real risks, so our studies take all ignition sources into account, not only electrical equipment.
Talk to a Hazardous Area Classification Consultant
Tell us about your facility, the materials you handle and your layout. We will come back within one working day with a clear scope for your classification study.
- IFC-approved, genuinely independent consultants
- IS 5572, IEC 60079, ATEX and NFPA practice
- Audit-ready zone drawings and an equipment schedule
- New plants, existing installations, expansions and shutdowns
Let's discuss
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