Safe Crack Removal in ATEX Zones

Controlled Crack Removal in Hazardous Areas

Crack removal in explosive environments requires a controlled process, precise tools, and continuous temperature monitoring. This case demonstrates how cracks can be followed and removed safely using ATEX-certified grinding and cutting tools, while monitoring both tool temperature and substrate temperature throughout the operation.

The method shown is suitable for maintenance and repair work in ATEX gas zones 1 and 2, where heat generation, sparks, and loss of control must be minimized.

Requested scenario from customer

Customer-Requested Crack Removal Scenario

In this scenario, the objective is to follow existing cracks and grind them out accurately, ensuring full crack removal without unnecessary material loss.

During the operation:

• Cracks are followed precisely using suitable grinding profiles

• Temperatures are monitored continuously

• Substrate temperature is checked to prevent overheatingThe process remains controlled and repeatable

This approach is commonly used in structural repairs, industrial maintenance, and inspection-driven corrective work.

ATEX-Certified Tools Used for Crack Removal

Grinding tools

The following grinding tools are used to follow and remove cracks with precision:

• A-0001 – Slim
  Ideal for narrow cracks and controlled material removal.

• A-0002 – Bow Cone
  Suitable for following curved crack profiles and transitions.

• A-0007 – Shorty
  Provides stability and control in confined areas.

• A-0005 – Round Boy
  Used for blending and smoothing after crack removal.

Cutting tools

For opening or removing material around cracks, the following tools are used:

• • A-0503 – Weld Removal Disc
    Enables controlled material removal with minimal heat generation.

  • A-0502 – Cutting Disc
    Used where defined cuts are required prior to grinding.

Demonstration of Crack Removal in ATEX Environment

The video below demonstrates the crack removal process step by step, showing tool selection, working technique, and temperature control during operation.