Explosion Proof Glands Australia: Choosing The Right Industrial Fit

Explosion proof glands in Australia play an essential role in keeping hazardous environments safe. Industries such as mining, oil and gas, and chemical processing rely on these fittings to prevent sparks, gases, or dust from escaping or entering electrical enclosures.

By sealing and securing cables, explosion-proof cable glands reduce the risk of ignition in explosive atmospheres while ensuring compliance with Australian standards. In this article, we’ll break down why they matter, the types available, how to select the right one, and the key regulations you need to know.

Why Do You Need Explosion-Proof Glands in Australia?

If you work around flammable gases or dusts (common in Australian mining, oil & gas, or chemical plants), standard cable connectors just won’t cut it. An explosion-proof (aka flameproof) gland is designed so that any explosion inside the enclosure cannot propagate outside. In other words, it contains any fire or spark within the equipment.

According to Eaton’s industry guide, cable glands in hazardous locations “provide the safe connection of suitable cables to enclosures, maintaining the explosion protection and ingress properties of equipment”. In practice, this means they seal the cable entry tightly, use thicker metal and special fill-compounds, and endure high pressures and heat without failing.

Australia’s own standards (AS/NZS 3000 and the 60079 series) are tough on this. They say that electrical installations in gas or dust zones must use certified explosion-protection techniques.

In fact, every time you slip a cable through a panel in a Zone 1 or Zone 2 area, the gland must be appropriately rated. One Aussie guide bluntly notes: if the standards don’t cover a detail, “the electrical equipment must be installed as per the manufacturer’s instructions”. In short, down here we can’t wing it – using a proper explosion proof gland is non-negotiable if there’s any chance of a combustible atmosphere.

Types of Explosion-Proof Cable Glands

Not all explosion-proof glands are the same. The choice depends on your cable and your hazard zone. Here are some common categories:

• Flameproof (Ex d) Glands: These are super-robust. The housing is thick (often cast brass or stainless steel) so any internal blast stays locked in. Use these for Zone 1 or even Zone 0 gas areas. They often require barrier seals (see below).
  
  

• Increased Safety (Ex e) Glands: Lighter-duty, with extra insulation and no hot-spots inside. Suitable for Zone 1/2 gas areas where you just need to avoid sparks.
  
  

• Intrinsic Safety (Ex i) Glands: Not “bomb-proof” by themselves, but designed to mate with intrinsically safe circuits (low energy). Common in instrumentation.
  
  

• Non-sparking (Ex nA/C) Glands: For simpler Zone 2 applications (less likely to ignite), these prevent any metal-on-metal sparking.
  
  

• Dust Ignition-proof (Ex t) Glands: If you have flammable dust (grain mills, wood dust, etc.), dust-proof glands comply with IEC/AS 60079-31.
  
  

These categories line up with standards. For example, AS/NZS (IEC) 60079-1 covers Ex “d” flameproof, 60079-7 covers Ex “e”, 60079-15 covers Ex “n”, and 60079-31 covers Ex “t” (dust). The table below summarizes this at a glance:

(Standards and zones in Australia align with IECEx/ATEX requirements.)

Aside from those, glands also come as barrier or compression types. A barrier gland is packed with a flameproof compound (epoxy or putty) around the cable, effectively isolating the conductors. This is often needed for Ex d glands on unarmoured cable.

A simpler compression gland just uses a rubber seal and metal parts to clamp the cable and keep out dust/water. For example, one manufacturer notes:

“Resin barrier glands in nickel-plated brass or stainless steel; Compression glands in polyamide/nylon/nickel-plated brass…”.

In plainer words: barrier (resin-filled) glands are usually brass or stainless to withstand heat, while simpler compression glands can even be nylon (for less severe conditions).

Here are a few common gland styles you’ll hear about:

• Resin (Barrier) Glands: Packed with potting compound for maximum seal. They often look just like regular glands but include a little epoxy well. As EX Engineering puts it, these can be nickel-brass or stainless steel and “completely wrap the cable by the putty compound, which can better achieve a sealing flameproof effect”.
  
  

• Compression Glands: The bread-and-butter cable gland. A tightening nut compresses rubber rings around the cable. Could be metal or even durable nylon (polyamide) for lighter duty.
  
  

• Armour-Locking Glands: Special glands for armoured cable (SWA/steel tape). They have a metal ring that grips the cable’s armour braid for grounding. You’ll see these used on heavy power cables – the “locking ring not locking onto the armour” is a common fault inspectors find if installed wrong.
  
  

 

Each kind is tailored for certain cables and zones. For instance, if your cable is armoured (SWG steel wire braid), use a gland with an armour clamp so the earth bond is solid (like the left side of the image above). If it’s unarmoured, you may need a gland with a barrier seal or at least multiple seals to prevent gas ingress (right side of image).

What Material Should I Choose?

Materials matter in the Aussie outback. A gland made of soft metal in a corrosive mine or offshore rig will just get eaten away. The main choices are:

• Brass (often nickel-plated): Cheaper, good general corrosion resistance. Common for indoor/industrial use. Nickel-plating adds extra rust resistance.
  

• Stainless Steel (often 316SS): Top-tier corrosion resistance. A must if you’re near salt spray (coastal oil rigs) or chemicals. Steel is strong too.
  

• Aluminum: Lightweight, not as strong or corrosion-resistant. Rare for explosion-proof (mostly in certain zones with lighter duty).
  

• Nylon/Polyamide: Non-metallic, used for small or low-energy glands (like Ex i). Not for high impact or very high-temp, but immune to most chemicals and very light.
  
  

Remember, the gland will see the environment – maybe 50°C heat, maybe salty air. Many manufacturers test for “corrosion resistance” against acids, alkalies and water vapor. For example, Apexio Industrial claims their explosion-proof glands are “designed to combat the effects of explosive gases and dusts, with acid, alkali, strong corrosive gas, or water vapour”. So if you expect chemical fumes or marine air, lean stainless. If it’s a dry warehouse, brass might be just fine.

Key Factors in Choosing the Right Gland

When you’re shopping for that perfect gland (online or in a catalog), don’t eyeball the specs alone. Here are the main things you need to match to your project:

• Hazard Zone/Class: What flammable stuff is around? Gas or dust? Zone 0/1/2 or 20/21/22? (Or Division I/II in IECEx lingo.) The gland must be rated for that exact environment.
  
  

• Enclosure Protection Type: Is the box Ex d (flameproof) or Ex e (increased safety) or something else? For example, an Ex d box needs an Ex d gland; you can’t skip to an Ex e gland on a flameproof enclosure.
  
  

• Cable Details: Diameter, insulation type, armour or not, any filler. The gland must clamp the cable snugly. Too small, and the seal gaps. Too big, and it won’t even tighten. Also check if the cable has a steel braid: if so, you’ll need that armour-locking type.
  
  

• Material vs. Environment: Will the gland sit outdoors? In seawater? Choose brass or SS accordingly. Also consider temperature range: if your site hits 80°C daily, make sure the gland’s temp rating covers that.
  
  

• Ingress Protection (IP) Rating: Most explosion-proof glands aim for at least IP66/68 (dust tight, waterproof). But confirm for wet environments or submersion (some glands can handle temporary flooding).
  
  

• Thread Type: Australia often uses metric threads (M-series) or NPT (American) for conduit. Make sure it fits your enclosure entry (M25, NPT3/4, etc).
  
  

• Certifications: Look for IECEx or ATEX approval badges. In Australia the relevant standards are AS/NZS 3000 and the IECEx/AS/NZS 60079 series. In short, your gland should have some third-party cert. Top suppliers boast testing to “IECEx, ATEX, UKEX, SANS, AS/NZS” standards. Don’t buy mystery imports without papers – inspectors will want to see them.
  
  

You can even make a mini checklist:

• Is the gland certified for the specific Zone (or Division) I need?
  

• Will it fit the cable outer diameter snugly (check min/max ranges)?
  

• Does it match the enclosure’s protection method (Ex d vs Ex e)?
  

• Is it made of a suitable material for the site’s corrosion and temp?
  

• Are all seals (O-rings, compund rings) supplied and appropriate?
  

• Finally: does it come from a reputable Aussie supplier or is at least IECEx-certified?
  
  

The point is: picking the wrong gland isn’t just buying the wrong size. It can break the explosion protection or earn non-compliance. One industry post bluntly reminds that AS/NZS 60079.14 requires exactly the right gland termination for Ex d systems – or you risk a failed inspection. In practice: always cross-check the cable type and protective gas/dust class with the manufacturer’s gland data.

Image: CNC machining an explosion-proof cable gland body. Quality glands often go through precise machining, plating and inspection.

It might seem overkill, but these glands are life-savers. After all, a single screw-up (literally a loose cable gland) can cost millions or lives if a fireball erupts.

How Explosion-Proof Glands Are Made

Before we wrap up the techie talk, a quick peek behind the scenes: good glands are built rigorously. One Australian supplier’s breakdown shows a typical process: cutting metal bars, CNC machining the body, threading the entries, deburring, then plating and engraving for traceability. Each part is inspected (“conformity check”) before assembling the gland and seals.

They even test things like pull-out strength (so your cable won’t slip out if yanked) and impact resistance (can it handle a dropped tool). In fact, their adverts highlight key qualities:

• Corrosion Resistant: Handles acid, alkali, water vapour, etc..
  

• Impact Resistant: Built to survive bumps and drops.
  

• Pull-out Resistant: Won’t give way if someone trips on the cable.
  
  

Basically, these glands are engineered to be tougher than nails in harsh Aussie conditions.

Anecdotes from Down Under

I once talked to an electrician who works on LNG plants in WA. He told me about the time a contractor tried to save a few bucks using a standard brass gland on a Zone 1 cable. Well, an inspector spotted it and bam – work stopped until the right Ex d/NPT gland showed up from Perth. Another friend in mining said their rig uses only stainless Ex d glands for all outdoor pumps – “We don’t trust anything less,” he laughed. The point is: Aussies don’t monkey around with explosion safety.

Actually, the regulator (called EEHA) in Australia has been cracking down on “barrier gland” installs. One consulting firm noted inspectors look for common mistakes: locking rings not tightened, putty not mixed right, NPT threads installed backwards, etc.. The moral? Even a perfect gland fails if installed wrong. Always follow the manufacturer’s torque specs and instructions. If in doubt, call their tech support. They know cable glands like we know pavlova recipes.

Regulations and Certification

All this technical gear has to meet official rules. In Australia, the AS/NZS standards are king (though they mirror IEC/EN). For example, AS/NZS 3000 (the Wiring Rules) explicitly requires using equipment certified for the specific classified area. That means your explosion-proof gland must come with documentation showing compliance. Many Aussie suppliers highlight IECEx certification – basically a gold badge accepted worldwide.

One industry site proudly states its glands are “third-party tested and certified” to standards including IECEx, ATEX, UKEX, AS/NZS, and more. That’s a mouthful, but basically means they’re upfront about safety. So when you see a gland labeled with, say, “IECEx CML 18.0018X” or an SAA tick mark, it’s not just marketing – it’s making sure the gear won’t get thrown out on the first safety audit.

When installing, remember: even the Standards say “follow the manufacturer”. In other words, AS/NZS 60079.14 notes that if the code doesn’t cover a detail, the gland maker’s instructions fill the gap. That could be specifying a special grease, a sealing washer, or how many threads must engage. It sounds pedantic, but that’s what prevents tiny leaks that could cause big booms.

Conclusion

Choosing the right explosion proof glands Australia depends on knowing your hazard, your cable, and your regs. It might seem like hunting for a needle in a haystack of specs, but think of it as your trench coat for the cable in a storm – it’s what keeps the dangerous bits out. We’ve covered why these glands are essential in Aussie industry (mines, gas, chemical plants), the different types you’ll encounter, and the checklist of factors to consider.

Bottom line: don’t cut corners. Use glands that are rated for the zone, sized correctly, and made of the right material. Always have them certified (IECEx/AS/NZS) and installed per instructions. That way you stay safe and compliant, and your project passes every inspection.

Feeling puzzled? Drop a comment below or chat with an electrical engineer (or even better, a supplier rep). After all, in hazardous work sites we're all in this together. Stay safe, mate!

Frequently Asked Questions

Q: What is an explosion proof cable gland?
A: It’s a heavy-duty cable entry device that seals and secures a cable in a hazardous zone. It prevents any spark inside equipment from igniting flammable gases or dust outside.

Q: Why use explosion proof glands in Australia?
A: Australia has many gas, oil, and mining sites where a stray spark is dangerous. Glands rated for explosive atmospheres are required by AS/NZS standards to keep you compliant and safe.

Q: How do I choose the right explosion-proof gland?
A: Match the gland to your cable type (armoured or not), zone (gas/dust classification), material needs (stainless for corrosion, etc.), and thread type. Always use one certified for the specific zone (e.g. Ex d for flameproof).

Q: Are explosion-proof glands reusable?
A: Generally, yes, but only if they are undamaged and complete (seals and compounds can sometimes be replaced). Always inspect O-rings and putty; if the gland shows wear or has been dropped, replace it.

Q: What certifications should explosion-proof glands have in Australia?
A: Look for IECEx or ATEX markings plus Australian-specific certs. At minimum they must comply with AS/NZS standards (e.g. AS/NZS 3000 and the IEC 60079 series). Sellers often list IECEx certificates on their data sheets