EX INDUSTRIAL VEHICLES CONVERSIONS

GALI ATEX industrial vehicles conversions

According ATEX directive

GALI, with more than 30 years of experience in the field, is specialist in the conversion of forklift trucks and other industrial vehicles, enabling them to operate in potentially explosive atmospheres (ATEX). Many industrial processes involve the possibility of generating gases and dust that, when mixed with air, can create an explosive atmosphere.

In such situations, any ignition source—such as an electrical arc, mechanical sparks, hot exhaust gases, static electricity, or high surface temperatures—can trigger an explosion.

Since 1994, the European Directive ATEX 94/92/EC has required companies to define these Zones and to protect all devices, installations, and mobile equipment that operate within them. The responsibility for this protection lies with the owners, managers, and health and safety officers. The ATEX Directive 2014/34/EU, known as ATEX, specifies the requirements for equipment used in Zones identified as potentially explosive atmospheres.

GALI, as a specialist in the protection of industrial vehicles, has developed a range of explosion-proof conversions, ensuring full compliance with the ATEX 2014/34/EU directive. We provide all necessary legal documentation with the vehicle, ensuring that all potential ignition sources are protected, and that the vehicle is safe to operate in a potentially explosive atmosphere.

Vehicles may include forklifts, aerial work platforms, cranes, scrubbers, tractors, side loaders, etc., and will be protected while ensuring minimal impact on their functionality. Only the minimum necessary modifications will be made.

To ensure adequate vehicle protection, we have a questionnaire that clearly indicates the different types of hazardous areas where the vehicle will operate.

General Features

  • GALI protection for all types of commercial vehicles according to the ATEX directive
  • Safety and environmental solutions
  • Custom-made explosion-proof protection
  • Diesel or electric forklift protection for Zone 1 or Zone 2

Downloads

Explosion proof conversions for industrial vehicles brochure

GALI offers safe protection for any electric or diesel industrial vehicle operating in Zone 1/21 and Zone 2/22 (gas or dust) in compliance with ATEX Directive 2014/34/EU.

ATEX zones for conversions
ATEX zone definitions scheme
GALI conversions ATEX zone ATEX category Gas classification Temperature class Definitions
GALITEX ZONE 1 2G IIA, IIB, IIB + H2, Gases, Vapours & Mists T1 (450°C)
T2 (300°C)
T3 (200°C)
T4 (135°C)
T5 (100°C)
T6 (85°C)
Locations where an explosive atmosphere is likely to occur during normal operation.
GALITEX or GALIGDS ZONE 2 3G IIA, IIB, IIB + H2, Gases, Vapours & Mists T1 (450°C)
T2 (300°C)
T3 (200°C)
T4 (135°C)
T5 (100°C)
T6 (85°C)
Locations where an explosive atmosphere is unlikely to occur during normal operation, but may occur for short periods.
GALIDUX ZONE 21 2D IIIA, IIIB, IIIC, Combustible Dust T 200°C
T 135°C
Locations where an explosive atmosphere is likely to occur during normal operation.
GALIDUX ZONE 22 3D IIIA, IIIB, IIIC, Combustible Dust T 200°C
T 135°C
Locations where an explosive atmosphere is unlikely to occur during normal operation, but may occur for short periods.

GALITEX CAT2G y CAT3G

ATEX Group II Zone 1 & Zone 2
Electric industrial vehicles
(passive safety)

GALI protects electrical industrial vehicles for safe operation in ATEX Zone 1 or ATEX Zone 2 areas of Group II (Industry). Areas where the presence of gas and vapors may create an ignition hazard.

In this electric vehicle protection, it is possible to combine Gas and Dust, with our GALITEX 3GD protection.

All potential ignition sources are protected to ensure the vehicle can operate safely in a potentially explosive atmosphere.

All possible ignition sources are protected to assure that the vehicle is safe to operate in a potential explosive atmosphere. Typical conversions include flameproof Ex d / Ex e enclosures, Ex d / Ex e motors (DC and AC), Ex e traction batteries, Ex i intrinsically safe electrical circuits, surface temperature control, stainless steel forks, etc. All conversions are carried out in compliance with the ATEX Directive 2014/34/EU and the harmonized standard EN 1755.

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GALITEX CAT2G y CAT3G

ATEX Group II Zone 1 & Zone 2
Diesel industrial vehicles
(passive safety)

GALI protects diesel industrial vehicles for safe operation in ATEX Zone 1 or ATEX Zone 2 areas of Group II (Industry). Areas where the presence of gas and vapors may create an ignition hazard.

All potential ignition sources are protected to ensure the vehicle can operate safely in a potentially explosive atmosphere.

All possible ignition sources are protected to assure that the vehicle is safe to operate in a potential explosive atmosphere. Typical conversion done in the vehicle may include flameproof Ex d / Ex e enclosures, Ex d / Ex nR starter motors, gases and coolant temperature control, Ex e / mb starter batteries, Ex d / tb alternator, inlet shutdown valve, inlet and exhaust flame arrestor, spark arrestor, exhaust gases heat exchanger, Ex i intrinsically safe electrical circuits, gases and coolant temperature control, stainless steel forks, etc. All of this in compliance with the ATEX Directive 2014/34/EU and the harmonized standard EN 1755 and EN 1834-1.

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GALIDUX CAT2D y CAT3D

ATEX Group II Zone 21 & Zone 22
Electric industrial vehicles
(passive safety)

GALI protects electrical industrial vehicles for safe operation in ATEX Zone 21 or ATEX Zone 22 areas of Group II (Industry). Areas where the presence of dust and powder may create an ignition hazard.

All potential ignition sources are protected to ensure the vehicle can operate safely in a potentially explosive atmosphere.

All possible ignition sources are protected to assure that the vehicle is safe to operate in a potential explosive atmosphere. Typical conversion done in the vehicle may include flameproof Ex tb / tc IP65 enclosures, Ex tb / tc IP65 motors (DC and AC), Ex tb / tc traction batteries with IP65 plugs, Ex i intrinsically safe electrical circuits, surface temperature control, stainless-steel cladded forks, etc. All of this in compliance with the ATEX Directive 2014/34/EU and the harmonized standard EN 1755.

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GALIDUX CAT2D y CAT3D

ATEX Group II Zone 21 & Zone 22
Diesel industrial vehicles
(passive safety)

GALI protects diesel industrial vehicles for safe operation in ATEX Zone 21 or ATEX Zone 22 of Group II (Industry). Areas where the presence of dust and powder may create an ignition hazard.

All potential ignition sources are protected to ensure the vehicle can operate safely in a potentially explosive atmosphere.

1) All possible ignition sources are protected to assure that the vehicle is safe to operate in a potential explosive atmosphere. Typical conversion done in the vehicle may include flameproof Ex tb / tc IP65 enclosures, Ex tb / tc IP65 starter motors, Ex e mb batteries, Ex d/Ex t alternator, spark arrestor, exhaust gases heat exchanger, Ex i intrinsically safe electrical circuits, gases and coolant temperature control, stainless steel forks, etc. All of this in compliance with the ATEX Directive 2014/34/EU and the harmonized standard EN 1755 and EN 1834-3.

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GALIGDS CAT3G

ATEX Group II Zone 2
Electric industrial vehicles
(active safety)

GALI protects electrical industrial vehicles for safe operation in ATEX Zone. Areas where the presence of dust and powder may create an ignition hazard.

Our GALIGDS system is an active protection system that informs the operator if the area is safe to work in. The conversion includes gas detectors that trigger a visual/audible alert to the operator, prompting them to exit the hazardous zone if gas/vapor is detected at 10% LEL.

If the gas/vapor reaches 25% LEL, the vehicle will proceed to stop in a controlled manner. Our GALIGAS system includes an automatic self-check test at the vehicle’s startup without the need to use a gas bottle, thus avoiding the high cost of consumables and simplifying installation.

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GALITEX M2

ATEX Group I
Mining vehicles
(passive safety)

GALI protects vehicles to work safely in ATEX Zone M2 of Group I (Mining). These are areas where the presence of methane gas (grisú) could create an ignition hazard.

All potential ignition sources are protected to ensure the vehicle can operate safely in a potentially explosive atmosphere.

Typical conversions for the vehicle may include: flameproof Ex d / Ex e enclosures, Ex d electric starters, Ex e / mb starting batteries, Ex d / e alternators, input shut-off valves, inlet and outlet flame arresters, spark arresters, exhaust gas heat exchangers, intrinsically safe Ex i electrical circuits, surface and gas temperature control. All of this complies with the ATEX Directive 2014/34/EU and the harmonized standards EN 1755 and EN 1834-2.

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