When custom-designed and certified, IoT systems — devices with embedded sensors that communicate across a network — can:

• Detect gas leaks, temperature spikes, or unsafe equipment conditions in real time.
• Reduce exposure by enabling remote operation and predictive maintenance.
• Improve emergency response with automated alerts that trigger early-warning systems with built-in ‘shut-down logic’.

At Ignitec, we design and build certified IoT products engineered specifically for explosive, high-risk, and moderately hazardous environments. By integrating electronics, firmware, mechanical systems, and certification requirements into a single solution, we ensure that each device is robust, reliable, and safe for deployment in the field or on the workplace floor. 

To make your operations safer and more resilient with IoT, book a complimentary discovery call with one of our engineers. We’ll help you evaluate the right approach for your environment. Alternatively, continue reading for additional safety tips and best practices for designing IoT systems in hazardous environments.

Expert tip #1: Start with an accurate hazard assessment

A hazardous environment is any setting where flammable gases, vapours, dust, or fibres create a risk of ignition or explosion. These environments are typically classified into zones based on the likelihood of a hazardous atmosphere. Zones are categories that indicate how often a dangerous substance may be present, guiding safety requirements.

In moderately hazardous environments, risks tend to be sporadic, making them easy to overlook; hence, the value of IoT-based continuous monitoring. By promptly evaluating hazard risks, designers and engineers can make informed decisions on materials, enclosure design, sensor type, and communication architecture.

Expert tip #2: Design power systems that cannot ignite under any condition

In hazardous locations, even microscopic sparks can trigger an ignition, and electrical energy is one of the most common ignition sources. To eliminate risk, IoT products in hazardous zones often rely on:

• Intrinsic safety (IEC 60079-11): Limits electrical and thermal energy in equipment so that ignition of a hazardous atmosphere is prevented, even under fault conditions.
• Flameproof / Explosion-proof housings (Ex d): These are special enclosures that contain any explosion inside the device, preventing the ignition of external hazardous gases or dust.
• Pressurised enclosures (Ex p): Prevent hazardous gases from entering the device

Design recommendations:

• Select low-power electronics and utilise firmware sleep cycles to minimize heat generation.
• Run thermal simulations early to prevent heat build-up inside compact housings.
• Add current limiting and galvanic isolation for fault protection.
• Only use components rated for the zone where the device will operate.

Power control is the cornerstone of safe IoT design in both high-risk and moderately hazardous environments. Explore Ignitec’s Intrinsically Safe Design Services to ensure uncompromising safety. 

Expert tip #3: Design enclosures built to withstand harsh conditions

The enclosure must prevent gas or dust ingress, withstand harsh environmental conditions, and, in some cases, contain an internal ignition event. Common failure risks include:

• Corrosion from chemicals or saltwater
• Fine dust infiltration into seals or cable entries
• Mechanical vibration or impact damage
• Poor heat dissipation resulting in internal ignition

Design recommendations:

• Select the appropriate protection concept: Ex d (flameproof), Ex e (increased safety), or Ex p (pressurised), depending on the environment. Each concept addresses specific hazards and operating conditions.
• Use materials proven for longevity — e.g., marine-grade stainless steel on offshore rigs or reinforced polymers in corrosive chemical plants.
• Validate designs with vibration, ingress (IP), and pressure tests.
• Support easy inspection without compromising certification — critical in industries where downtime is expensive.

A robust, custom enclosure design shields internal electronics and safeguards personnel in hazardous environments. Rely on best-in-class engineering to address both aspects effectively.

Expert tip #4: Rigorously test for reliable performance under stress

Hazardous environments, even those deemed only moderately risky, are rarely stable. Devices may be required to operate:

• In sustained high heat
• In salt-fog marine air
• With heavy vibration (e.g., in mining vehicles)
• Or in humid, dusty, or enclosed spaces

Design recommendations to ensure reliability:

• Use industrial-grade components and conformal coatings, which are protective chemical layers applied to circuit boards, for corrosion resistance.
• Use accelerated life testing (ALT), a method that subjects devices to extreme conditions to rapidly predict performance over time and identify potential failure points.
• Build remote monitoring and diagnostics features so maintenance teams can identify when intervention is needed — without entering a hazardous environment.

Testing for reliability goes beyond laboratory durability. Insist on real-world validation—even on-site in operational hazardous environments—to guarantee safety and prevent failure events.

Expert tip #5: Choose connectivity methods that work where signals struggle

Connectivity challenges, especially in remote areas, are exacerbated in hazardous zones: steel structures, sealed rooms, and remote locations all interfere with signal performance, and a loss of connectivity can compromise safety if systems rely solely on cloud-based logic.

Design recommendations for best practice:

• Ensure antennas and radio modules are certified for Ex environments (where Ex means equipment designed for use in explosive atmospheres), or position antennas safely outside hazardous zones.
• Use network architectures that account for signal loss, such as mesh networks, where devices connect to each other to extend range, or LoRaWAN, a long-range wireless protocol for low-power devices.
• Incorporate edge processing so devices remain functional during connectivity interruptions.
• Perform RF propagation surveys before deployment.

Our objective is independent communication: a secure data pipeline that guarantees situational awareness, operational transparency, and reliable analytics—even in remote locations.

Expert tip #6: Design for certification, maintenance, and lifecycle support from day 1

Compliance frameworks (for example, UKCA or UKEX) govern the design and testing of equipment. UKCA is the UK Conformity Assessed marking for products, and UKEX is a certification for equipment used in explosive atmospheres. Well-designed IoT systems streamline regulatory certification readiness, asset tracking and audit records, predictive maintenance scheduling, and condition-based monitoring alerts.

Designing IoT solutions for hazardous environments in this manner reduces maintenance access risks and operating costs (e.g., the cost of certified replacement parts) and lowers downtime resulting from equipment shutdowns. 

Design recommendations:

• Involve certification experts early.
• Design with pre-certified subassemblies where appropriate.
• Document traceability of materials, tolerances, and design controls.
• Partner with testing labs experienced in hazardous environments.

IoT advantage #7: Always prioritise safety

IoT in hazardous environments isn’t just about adding ‘smart features’. It’s about enabling safer operations, improving decision-making, reducing exposure to risk, and lowering maintenance costs – all of which increase uptime and productivity.

Design recommendations:

• Failsafe logic and watchdog recovery.
• Secure OTA updates to prevent cyber-physical compromise.
• Local decisions take precedence over cloud logic.

Ensure all smart features strictly enhance the protection of products and users; safety enhancement is a non-negotiable design imperative.

Final thoughts on designing IoT for hazardous environments

Industrial safety and operational resilience demand connected, certified, and purpose-built technology. Designed and deployed with expertise, IoT systems mitigate risk, protect workers, and enable sustainable, confident operations in hazardous environments.

At Ignitec, our engineers take products from concept to certification and deployment — ensuring that every device is safe, smart, compliant, and ready for the demands of real-world use.

Talk to an IoT product design expert

If you’re developing IoT for hazardous environments and need guidance on concept, compliance, or certification, schedule a free consultation with one of our engineers. We’ll help you evaluate your environment, assess feasibility, and determine the safest and most cost-effective path forward.