Ten Common Mistakes People Make in Hazardous Areas

Hazardous area safety demands continuous vigilance, competency and respect for procedures. Small errors can have large consequences, but most incidents are preventable with the right awareness and discipline. By understanding these common safety violations and taking proactive steps to avoid them, we can build safer workplaces and protect lives, property and reputation.

Here are ten of the most common mistakes people make when working in hazardous areas and why it is critical to avoid them:

1. Lack of Hazard Awareness

Each hazardous environment has specific risks that must be clearly understood before work begins. Workers sometimes assume that because they have worked safely elsewhere, they can apply the same practices here. This assumption can lead to gaps in hazardous area safety protocols.

2. Ignoring Area Classification (HAC)

Hazardous areas are classified according to the likelihood and duration of explosive atmospheres being present — such as Zone 0, 1, 2 for gases, or Zone 20, 21, 22 for dusts. Failing to understand HAC can result in the use of inappropriate equipment and unsafe work practices.

3. Using Non-Certified Equipment

Using non-certified equipment can introduce ignition sources — for example, portable lights, power tools, or phones. Equipment must meet the specific certification standards of the hazardous area in which it is being used.

4. Poor Installation Practices

Installation carried out by workers in hazardous areas who have not undertaken the requisite competency-based training for installing and maintaining Ex equipment can compromise the protection integrity of Ex-certified equipment. This underlines the importance of hazardous area training and strict adherence to hazardous environment protocols.

5. Inadequate Maintenance and Inspections

Regular maintenance and inspections are essential, as degradation over time can create hidden dangers. Seals can degrade, enclosures may become compromised, and fittings can loosen. Neglecting inspections or maintenance can allow risks to develop unnoticed — a preventable common safety violation.

6. Unauthorised Modifications

Unauthorised modifications to certified equipment, even minor changes, can invalidate certification and expose the area to risk. Even simple actions like replacing bolts or seals with non-approved parts can introduce significant hazards — a clear breach of hazardous area safety standards.

7. Inadequate Permit to Work (PTW) Systems

Implementing a Permit to Work system when conducting hazardous tasks such as hot work, electrical isolation, or confined space entry ensures the safety of the installation and the worker. Failing to implement or properly follow a PTW system undermines layers of protection — a critical industrial safety mistake.

8. Poor Training and Competency

To work on Electrical Equipment in Hazardous Areas (EEHA) requires specific units of competency as per AS/NZS 60079.14. Relying on general electrical or mechanical skills without specialist hazardous area training can lead to unsafe decisions and non-compliance. PMV offers specialised hazardous area courses designed to address this gap in skills and understanding.

9. Overlooking Static Electricity Risks

AS/NZS 3000 places emphasis on static electricity and equipotential bonding and earthing. Improper bonding and earthing practices can create dangerous conditions for ignition. Understanding these systems is vital when working in hazardous areas.

10. Complacency and Routine Mindset

Complacency — a mindset of treating high-risk work as routine — can lead to shortcuts, missed checks, and preventable incidents. Cultivating a safety-first culture is essential in maintaining hazardous area safety at every level.

Whether you’re an experienced technician or new to the industry, it’s vital to stay updated, stay aware and stay compliant. Many of these mistakes stem from assumptions, lack of training, or simply getting too comfortable with the work. That’s why ongoing education through recognised hazardous area courses like those offered by PMV Training, plays a key role in building safer, more resilient teams.

After all, when it comes to hazardous area safety, there are no shortcuts, only smart decisions backed by the right knowledge and a commitment to doing things the right way, every time.