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Explosion protection document template (PDF & Excel) with zone register

Fill-in structure for the explosion protection document in Germany – with substances and safety parameters, areas and zones, the 13 types of ignition source in TRGS 723, technical and organisational measures, inspections, revision log and approval.

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If hazardous explosive mixtures can occur during work, the employer must set out the explosion hazards separately in the risk assessment (Gefährdungsbeurteilung) – in the explosion protection document (Explosionsschutzdokument) under Section 6 (9) of the Hazardous Substances Ordinance (GefStoffV). Among other things, it must show that the hazards have been assessed, which explosion protection concept applies, which areas are classified into zones and which inspections under the Ordinance on Industrial Safety and Health (BetrSichV) are due. It must exist before work first starts.

This template provides its own fill-in structure, based on the layout of DGUV Information 213-106: area and process, substance data, assessment, zones, ignition sources, measures, inspections, revision log and approval. The Excel file holds the zone register with the minimum equipment category determined automatically and an inspection plan with due dates.

What the template contains

  • Landscape PDF with header data, description of area and process and a table of substances with flash point, explosion limits and ignition temperature
  • Assessment questions, overview of zones with equipment categories and an area table with source of release, zone and extent
  • Ignition source table with the 13 types of ignition source in TRGS 723, technical measures and a checklist of eleven organisational measures
  • Inspection plan under Annex 2 Section 3 BetrSichV and Section 7 (7) GefStoffV, related documents, revision log and approval
  • Excel zone register with drop-down lists and automatic equipment category, plus an inspection plan that calculates the next inspection

How to use the template

  1. 1

    Record area and substances

    For each plant section or installation, describe the location, process and activities – including cleaning, maintenance and faults. Enter the flammable substances with their safety parameters; flash point, explosion limits and ignition temperature are usually in section 9 of the safety data sheet.

  2. 2

    Assess and define zones

    Answer the assessment questions and determine where hazardous explosive atmospheres can occur – starting from the situation without protective measures such as technical ventilation (DGUV Information 213-106). Classify the areas into zones, assess the ignition sources and define technical and organisational measures.

  3. 3

    Plan inspections and approve

    Enter the inspections with their intervals and keep the inspection plan up to date in Excel. The author, the person responsible for the area and the employer sign before work starts; record every review and change in the revision log.

Hazardous substances management in AMS GoManage safety data sheets centrally and have AI extract classification, H statements, storage class and protective measures with source references – adopted only after review and approval by a competent person.

Legal basis

  • Section 6 (4), (8), (9) and (10) of the Hazardous Substances Ordinance: assessment of fire and explosion hazards, explosion protection document, documentation before work starts, updating
  • Section 12 and Annex I No. 1 of the Hazardous Substances Ordinance: order of priority in explosion protection, organisational measures, marking, zoning and equipment categories
  • Annex 2 Section 3 of the Ordinance on Industrial Safety and Health: inspections before commissioning, at least every six years and of equipment, ventilation, gas detection and inerting systems
  • TRGS 720 to 725: assessing explosion hazards, avoiding explosive mixtures and effective ignition sources, constructional explosion protection, measuring and control devices
  • DGUV Information 213-106 “Explosion protection document” (Explosionsschutzdokument): structure and contents

Frequently asked questions

When do I need an explosion protection document?

When hazardous explosive mixtures can form during work and this is not already reliably prevented by tightness, natural ventilation or organisational measures (TRGS 720). Typical examples are painting and filling areas, solvent stores or dust-carrying installations such as mills, silos and extraction systems. If no hazardous explosive atmosphere can form, a note in the risk assessment is sufficient.

Do I have to draw the zones on a plan?

The Hazardous Substances Ordinance requires the zoning to be documented in the explosion protection document (Annex I No. 1.7); it does not prescribe a format. Many companies add a zone plan based on the site or building plan to the table and attach it. If you do not classify an area into zones, measures as for zone 0 or 20 apply unless the risk assessment specifies otherwise.

Who inspects installations in hazardous areas?

Before first commissioning and at least every six years, an approved inspection body (zugelassene Überwachungsstelle, ZÜS) or a person qualified to carry out inspections with special qualifications in explosion protection inspects explosion safety; for installations requiring a permit, such as large storage facilities or petrol stations, only the ZÜS. A qualified person inspects equipment and protective systems at least every three years, and ventilation, gas detection and inerting systems annually (Annex 2 Section 3 BetrSichV).

You may use and adapt the template freely in your own company and for your own clients. It reflects the regulations named as they stand.

Never search a spreadsheet for a deadline again

In AMS Go, what this template covers lives in one system with reminders, history and records at the push of a button – mobile and with AI support.

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