Hazardous Area Cable Gland Selection: Material & Certification Requirements You Must Know

In hazardous areas—where explosive gases, flammable dust, or corrosive substances pose constant threats to electrical systems—cable glands are far more than simple connectors. These critical components seal cable entry points, prevent the ingress of hazardous materials, and maintain the integrity of explosion-proof or flameproof enclosures, directly safeguarding personnel, equipment, and operations. Yet, selecting the right cable gland for such high-risk environments is not a choice to be made lightly: two non-negotiable pillars—material durability and global certification compliance—determine whether a cable gland will perform reliably or become a catastrophic weak link. This guide breaks down the essential material requirements and certification standards you must prioritize to ensure safety and compliance in hazardous zones.
 
Material Requirements: Built to Withstand Hazardous Environments
 
Hazardous areas expose cable glands to extreme conditions—from corrosive chemicals in petrochemical plants to abrasive dust in grain silos and temperature swings in offshore oil rigs. The material of a cable gland directly impacts its resistance, longevity, and ability to maintain sealing performance. Below are the key materials and their critical roles:
Metallic Materials: For High-Strength, Explosion-Proof Needs
Metals remain the gold standard for Zone 0, 1 (gas-explosive environments) and Zone 20, 21 (dust-explosive environments) due to their rigidity and ability to contain potential sparks.

Brass: Cost-effective and corrosion-resistant for general hazardous areas (e.g., chemical storage facilities). It offers good machinability, making it ideal for standard cable sizes.

Stainless Steel (304/316): The top choice for harsh, corrosive environments—such as offshore platforms, marine hazardous zones, or chemical processing plants. Its resistance to saltwater, acids, and extreme temperatures (-50°C to 150°C) ensures long-term reliability, even in continuous exposure.

Aluminum: Lightweight and cost-efficient for low-corrosion hazardous areas (e.g., mining operations with dry dust). It is often coated with epoxy to enhance durability.
Non-Metallic Materials: For Specialized Flexibility & Corrosion Resistance
Non-metals excel in applications where weight, chemical resistance, or electrical insulation is critical, particularly in Zone 2 (gas) and Zone 22 (dust) areas.
Nylon (PA6/PA66): High-impact strength and resistance to oils, fuels, and mild chemicals make it suitable for industrial control panels in hazardous zones. It also offers good thermal stability (up to 120°C).

Polypropylene (PP): Unaffected by most acids, alkalis, and solvents, making it ideal for pharmaceutical or chemical plants where aggressive substances are present. It is lightweight and offers excellent electrical insulation.
 
Certification Requirements: Ensuring Global Compliance & Safety
 
Material performance alone is insufficient—hazardous area cable glands must meet strict global certification standards to validate their ability to prevent explosions and comply with regional regulations. Choosing uncertified products not only risks non-compliance penalties but also endangers lives. Here are the most critical certifications to verify:
ATEX (European Union): The primary standard for hazardous areas in the EU and EEA. Certifications are categorized by:
Zone Classification: Gas (IIC for the most severe, IIB, IIA) and Dust (IIIC, IIIB, IIIA) to match the hazard level of your environment.
Equipment Protection Level (EPL): For example, "Ga" (highest protection) for Zone 0, "Gb" for Zone 1, and "Gc" for Zone 2 (gas zones); "Da" for Zone 20, "Db" for Zone 21, "Dc" for Zone 22 (dust zones). A valid ATEX certificate ensures the cable gland meets explosion-proof or flameproof requirements for its designated zone.
IECEx (International Electrotechnical Commission): A global certification scheme recognized in over 80 countries (including Australia, Brazil, China, and Southeast Asian nations). IECEx certification aligns with IEC standards (e.g., IEC 60079) and simplifies cross-border procurement, as it eliminates the need for multiple regional certifications. Look for the IECEx "Ex" mark on the product and accompanying certificate.
UL/CSA (North America): For hazardous areas in the U.S. and Canada, cable glands must meet UL (Underwriters Laboratories) or CSA (Canadian Standards Association) standards. Key certifications include:
UL 1203: For explosion-proof equipment in Class I (gas), Class II (dust), and Class III (fibers) hazardous locations.
CSA C22.2 No. 213: The Canadian equivalent of UL 1203, ensuring compliance with Canadian Electrical Code (CEC) requirements. These certifications confirm the cable gland can withstand pressure, prevent spark propagation, and resist environmental stress in North American hazardous zones.
Other Regional Certifications: Depending on your target market, verify additional standards:
GOST-R: For Russia and Eurasian Economic Union (EAEU) countries.
KCS: For South Korea.
SAA: For Australia and New Zealand (often aligned with IECEx).
 
Why Material & Certification Alignment Matters
 
Choosing a cable gland that matches both the environment’s material demands and regional certifications is not just a compliance box-ticking exercise—it directly impacts operational continuity and safety. For example:
A brass cable gland used in a saltwater-based hazardous zone (e.g., offshore oil rig) will corrode quickly, leading to seal failure and potential explosions.
An uncertified cable gland in a European chemical plant will violate ATEX regulations, resulting in fines, production shutdowns, or even legal liability in the event of an accident.
 
Final Takeaway
 
When selecting cable glands for hazardous areas, never compromise on material suitability or certification validity. Start by assessing your environment’s specific risks (corrosion, temperature, hazard type) to narrow down material options, then verify that the product holds the necessary certifications for your target market. By prioritizing these two pillars, you ensure that your cable glands not only meet global standards but also act as a reliable barrier against the unique dangers of hazardous zones.
Need help comparing specific material options or verifying certification validity for your project? I can assist with a tailored analysis based on your industry and target region.