Electrical Safety in Industrial Environments: High-Risk Areas Explained

Electrical systems in industrial settings are powerful, complex, and often exposed to harsh conditions. When things go wrong, the consequences can be severe. That’s why electrical safety in industrial environments—particularly in high-risk areas—must be a top priority.

Whether you're operating a factory, warehouse, or processing plant, this guide breaks down the most hazardous areas and outlines practical safety measures to keep people, property, and production protected.

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Why High-Risk Areas Demand Special Attention

In industrial sites, electricity is everywhere—powering machines, lighting, HVAC systems, and automated equipment. But high-risk zones like wet areas, confined spaces, or environments with explosive dust or fumes pose extra danger. Common risks include:

• Electric shock or arc flash

• Equipment damage and fire

• Downtime due to unexpected failure

• Legal action due to non-compliance

UK legislation such as the Electricity at Work Regulations 1989 and BS 7671 (IET Wiring Regulations) requires employers to ensure electrical systems are properly designed, maintained and safely used—especially in hazardous areas.

What Are the High-Risk Areas in Industrial Environments?

1. Wet or Damp Locations

Water increases conductivity, making even low-voltage systems dangerous. High-risk areas include food processing zones, washdown areas, and loading bays exposed to the elements.

Safety measures:

• Use IP-rated equipment

• Install residual current devices (RCDs)

• Ensure cable glands and enclosures are watertight

2. Explosive or Flammable Atmospheres (ATEX Zones)

Industrial processes involving chemicals, gases, or fine dust can create explosive conditions.

Safety measures:

• Use ATEX-certified equipment

• Bond and earth all systems properly

• Control ignition sources and install gas detection systems

3. Confined Spaces

Tanks, ducts, or service voids limit ventilation and escape routes, increasing the risk during electrical work.

Safety measures:

• Use low-voltage or battery-powered tools

• Isolate circuits fully before entry

• Follow permit-to-work systems

4. High-Voltage Equipment Zones

Areas with machinery running above 400V require strict control due to the increased danger of arc flash and severe injury.

Safety measures:

• Ensure secure access control and signage

• Implement lockout/tagout procedures

• Train staff on arc flash PPE and emergency response

5. Areas with Mechanical Vibration or Heavy Movement

Machinery vibration can loosen connections and wear down insulation—leading to faults or shorts.

Safety measures:

• Use reinforced cabling and flexible conduit

• Perform regular inspections and torque checks

• Anchor components securely

Best Practices for Electrical Safety in High-Risk Industrial Areas

• Conduct Regular Electrical Safety Audits: Professional audits identify risks before they cause harm—especially useful in older facilities or sites that have changed over time.

• Implement Planned Preventative Maintenance (PPM): A PPM schedule helps keep equipment in peak condition, reducing the risk of failure and extending system life.

• Train Staff in Electrical Awareness: All site workers—not just electricians—should know how to recognise hazards, report faults, and follow safe practices.

• Enforce Lockout/Tagout (LOTO): LOTO procedures are essential for isolating live circuits during maintenance or repair. Use visible lockout kits and signage.

• Label and Document Everything

• Clear labelling of circuits, isolators, and panels makes systems easier to maintain and safer to operate.

Why Choose Carter’s Electrical Services?

We work with industrial clients across Oxfordshire and the UK to ensure their sites are electrically safe, fully compliant, and well maintained. From ATEX installations to full PPM schedules, we offer peace of mind in even the most demanding environments.

📞 Contact us today to arrange an inspection or discuss your electrical safety requirements.

 

Frequently Asked Questions

• What is considered a high-risk electrical area in industry?

  Any location where conditions increase the risk of electric shock, fire, or explosion—such as wet zones, ATEX environments, or confined spaces.

• What regulations govern industrial electrical safety in the UK?

  The Electricity at Work Regulations 1989 and BS 7671 (Wiring Regulations) are the key legal frameworks. ATEX applies in explosive environments.

• How often should electrical systems be tested in industrial sites?

  Typically every 3 years, though high-risk areas may require more frequent inspection or ongoing maintenance.

• What is ATEX and do I need to comply?

  ATEX refers to EU/UK standards for equipment used in explosive atmospheres. If your site involves flammable dust, gas or chemicals—you must comply.

• Can you retrofit high-risk safety upgrades into existing sites?

  Yes. We can assess your current systems and install protective equipment, labelling, isolators, and compliant enclosures to meet safety standards.