Fire compartments, ATEX zones and safety plans: how to build a coherent site map

A fire compartment is a building or part of it separated from other buildings or spaces by fire-resisting separation elements, or the required open separation area under applicable building rules. Its boundary is not simply a department or production-line boundary. It comes from technical documentation and the actual fire protection arrangements.

Distinguish compartment boundaries, fire walls and closures, escape routes and exits, extinguishers, hydrants, manual fire alarm call points, fire-service electrical isolation controls, assembly points and responder access. A call point activates an alarm; an electrical isolation control has a different function and a scope defined by the design.

R, E and I refer to load-bearing capacity, integrity and insulation; the number gives time in minutes. Not every element is classified REI: its designation depends on the element and design requirements. Fire load density also requires material data and an appropriate calculation method, not a visual estimate.

The drawn escape route must match an accessible route on site, without obstructed doors, stored pallets or arrows through solid walls. ISO 7010 signs help identify safety information; a sign library alone does not certify an entire plan.

An explosive atmosphere is a mixture with air, under atmospheric conditions, of flammable substances as gases, vapours, mists or dusts, in which combustion spreads to the entire unburned mixture after ignition. ATEX covers both worker protection and equipment requirements; a zone number is not an equipment category number.

For gases, vapours and mists: zone 0 means an explosive atmosphere is present continuously, for long periods or frequently. Zone 1 means it is likely to occur occasionally in normal operation. Zone 2 means it is not likely in normal operation, but if it occurs it persists only briefly.

For a cloud of combustible dust in air the equivalent zones are 20, 21 and 22: continuous, long-lasting or frequent for 20; occasional in normal operation for 21; unlikely in normal operation and brief if it occurs for 22. Layers, deposits and heaps of combustible dust must also be considered as possible sources.

The zone number describes occurrence frequency and duration, not simply the severity of a possible explosion. Extent and height depend on releases, substances, ventilation and process conditions. There is no universal radius to draw around every vessel or silo.

Transfer the approved classification from the risk assessment and explosion protection document onto the map, with area identifiers and sources. Hot work, maintenance and contractor activities require the relevant procedures and PTW where specified. An ordinary smartphone is not automatically suitable for an Ex zone: put QR/NFC access outside it or use equipment properly selected for the zone and conditions.

A LOTO map links the machine identifier to its actual energy-isolating devices: disconnectors, valves or other points specified by the procedure. Consider all relevant energy types, including electrical, pneumatic, hydraulic, mechanical, thermal and stored energy. A STOP button or emergency stop alone is not energy isolation.

The drawing helps locate a point and its instruction; it does not perform the lockout. Work still requires isolation, protection against re-energisation, release or restraint of residual energy and verification under the procedure. Identifiers on the plan, equipment and LOTO card must agree.

The chemical layer should show actual storage, SDS access, emergency equipment and storage restrictions. GHS pictograms come from the classification of the specific substance or mixture, not decorative labels for a whole store. Review relevant SDS information, including sections 5, 6, 7 and 10, for fire, release, handling and incompatible materials.

A shared location reference helps maintenance, EHS and quality. It does not make a chemical store an isolation point, or automatically assign every flammable substance a particular ATEX zone.

1) Collect a current floor plan and source documents: fire instructions, ATEX classification, explosion protection document, isolation procedures and chemical register. Check scale, orientation, room names and agreement with the site. Export CAD into a readable format supported by the chosen tool when needed.

2) Separate evacuation and fire protection, ATEX, energy and LOTO, chemicals and inspection layers. 3) Assign stable point identifiers and verify them on site; do not copy extinguisher and valve positions solely from an old file.

4) Link points to the correct instructions, SDS and responsibilities. 5) Establish who approves the content and what workers or contractors can see. Record the edition, review date and map owner; do not publicly expose confidential whole-site plans.

6) Test QR/NFC where it will be used and run a trial inspection. A report must identify a real area and a location someone can find. Keep accessible on-site instructions and arrangements for loss of network, power or phone access.

Where an IBP is required in Poland, fire regulations require updating it at least every two years and after changes in building use or technological processes that affect fire safety conditions. This does not justify leaving an extinguisher in the wrong position on a map until the next scheduled review.

Do not automatically apply the same two-year interval to ATEX. Review the assessment and explosion protection document after significant changes to substances, ventilation, equipment or work organisation. The zoning may change even if the building walls do not.

Common problems include confusing fire compartments with Ex zones, unreadable legends, missing edition dates, overlooked residual energy, broken SDS links and whole-site access for every visitor. Check documents, physical labels and whether a person who did not create the map can locate its points.

Safety plans and zones lets teams place areas and safety signs on a floor plan, link points to documentation and access plans in the field through QR/NFC. With the chemical module, locations can link to SDS; safety walks and reports identify defects in a particular place rather than vaguely near a production line.

Use the map for contractor briefings, fire equipment checks and preparing work requiring PTW. Visible information should match the role and area; connections depend on the modules in use. V-IMS organises access to approved data, but does not calculate fire-resistance classes for a designer or replace competent ATEX zoning assessment.

It is a shared tool for EHS, SHE/QHSE, engineering, quality and food safety. Start with one area's plans, then extend the connections to chemicals, inspections and corrective actions.