Intrinsically Safe Equipment Market

Market Definition

The market encompasses a range of devices and systems designed for use in hazardous environments where flammable gases, vapors, or dust may be present. This market includes equipment for various classified zones and classes, based on the duration of exposure to explosive atmospheres.

The market spans a broad product range, including sensors, detectors, switches, transmitters, isolators, LED indicators, and other supporting components that ensure safe operation in explosive conditions. The report outlines primary drivers of the market, along with an in-depth analysis of emerging trends and evolving regulatory frameworks shaping the market's trajectory.

Intrinsically Safe Equipment Market Overview

The global intrinsically safe equipment market size was valued at USD 3780.5 million in 2024 and is projected to grow from USD 4042.9 million in 2025 to USD 6568.7 million by 2032, exhibiting a CAGR of 7.11% during the forecast period.

This growth is attributed to increasing industrial automation in hazardous environments. The growth of the market is supported by rising investments in oil & gas, mining, and chemical industries where safety compliance is critical. Rising investments in oil & gas, mining, and chemical industries where safety compliance is essential are supporting market expansion.

Major companies operating in the intrinsically safe equipment industry are Emerson Electric Co., Drägerwerk AG & Co. KGaA, Rockwell Automation, Extronics, KROHNE, Pepperl+Fuchs SE, MSA, Siemens, Eaton, R. STAHL AG, Phoenix Contact, Schneider Electric, BARTEC Top Holding GmbH, Honeywell International Inc., and ABB.

Additionally, advances in wireless communication and sensor technologies are significantly boosting demand for intrinsically safe devices. These innovations enable seamless and reliable data transmission in hazardous environments, improving real-time monitoring capabilities. Enhanced sensor accuracy and connectivity allow businesses to optimize operational processes, reduce manual interventions, and increase safety compliance.

As a result, companies can achieve higher efficiency and lower operational risks, driving investment in intrinsically safe equipment that are equipped with the latest wireless and sensor technologies.

• In November 2023, Amazon Web Services, Inc. introduced Ex-rated sensors as a part of its Amazon Monitron system. These intrinsically safe sensors hold certifications for use in the U.S., Canada, UK, and EU, targeting gas-related hazardous areas classified as Class 1/Zone 2.

Key Highlights:

1. The intrinsically safe equipment industry size was valued at USD 3780.5 million in 2024.
2. The market is projected to grow at a CAGR of 7.11% from 2025 to 2032.
3. North America held a market share of 34.09% in 2024, with a valuation of USD 1288.6 million.
4. The zone 0 segment garnered USD 1130.4 million in revenue in 2024.
5. The class 1 segment is expected to reach USD 2529.0 million by 2032.
6. The sensors segment is expected to reach USD 1595.6 million by 2032.
7. The oil & gas segment is expected to reach USD 1415.6 million by 2032.
8. The market in Asia Pacific is anticipated to grow at a CAGR of 8.10% during the forecast period.

Market Driver

Rising Demand for Two-way Radios to Enhance Communication Efficiency

The intrinsically safe equipment market is driven by the increasing demand for two-way radios that enhance communication efficiency in hazardous environments. These radios are vital in industries such as oil & gas, mining, and chemical processing, where reliable and real-time communication is critical for safety and coordination.

Intrinsically safe two-way radios are designed to operate without generating heat or sparks that could ignite flammable gases, vapors, or dust. They ensure uninterrupted communication during routine operations, emergency responses, and maintenance tasks in classified zones. As industries modernize and move toward connected systems, the demand for certified and high-performance intrinsically safe products continue to rise.

• In November 2023, Hytera Communications unveiled its latest series of intrinsically safe two-way radios, featuring the HP79XEx DMR Portable Radio and PT890Ex TETRA Portable Radio. Built to comply with rigorous IECEX and ATEX explosion-proof certifications, these radios are designed to improve personnel safety and ensure reliable communication in high-risk industries like oil & gas, mining, chemical processing, and pharmaceuticals.

Market Challenge

High Initial Costs Limiting Intrinsically Safe Equipment Adoption

A significant challenge faced by the intrinsically safe equipment market is the high upfront costs of certified devices compared to standard equipment. These expenses can deter small and medium-sized enterprises from investing in intrinsically safe solutions, slowing market penetration in certain regions and industries.

Manufacturers are focusing on developing cost-effective designs without compromising on safety. Additionally, offering flexible financing options and focusing on the long-term cost savings from reduced downtime and accident risks are helping increase adoption rates across various sectors.

Market Trend

Adoption of Smart Glasses by Frontline Workers

The adoption of smart glasses by frontline workers is emerging as a significant trend in the intrinsically safe equipment market. These smart glasses provide hands-free access to critical information, enabling workers to perform tasks efficiently while maintaining safety in hazardous environments.

Designed to meet intrinsic safety standards, they prevent sparks or heat that could trigger explosions. This improves real-time communication and data sharing, reducing errors and downtime. As industries focus on enhancing worker productivity and safety, smart glasses are becoming an essential tool in sectors like oil & gas, mining, and chemical processing.

• In August 2023, RealWear, Inc. launched the RealWear Navigator Z1 and its next-generation intrinsically safe wearable headset designed for frontline workers in hazardous industries. Certified for use in explosive and combustible environments, the hands-free device integrates AI capabilities and 5G connectivity to enhance safety, operational efficiency, and remote collaboration.

Intrinsically Safe Equipment Market Report Snapshot

Segmentation	Details
By Zone	Zone 0, Zone 20, Zone 1, Zone 21, Zone 2, Zone 22
By Class	Class 1, Class 2, Class 3
By Product	Sensors, Detectors, Switches, Transmitters, Isolators, LED Indicators, Others
By End User	Oil & Gas, Mining, Power, Chemical & Petrochemical, Processing, Others
By Region	North America: U.S., Canada, Mexico
	Europe: France, UK, Spain, Germany, Italy, Russia, Rest of Europe
	Asia-Pacific: China, Japan, India, Australia, ASEAN, South Korea, Rest of Asia-Pacific
	Middle East & Africa: Turkey, U.A.E., Saudi Arabia, South Africa, Rest of Middle East & Africa
	South America: Brazil, Argentina, Rest of South America

Market Segmentation:

• By Zone (Zone 0, Zone 20, Zone 1, Zone 21, Zone 2, and Zone 22): The zone 0 segment earned USD 1130.4 million in 2024, on account of rising investments in upstream oil & gas exploration activities in high-risk environments.
• By Class (Class 1, Class 2, and Class 3): The class 1 segment held 38.45% share of the market in 2024, due to its widespread application in industries handling flammable gases and vapors.
• By Product (Sensors, Detectors, Switches, Transmitters, Isolators, LED Indicators, and Others): The sensors segment is projected to reach USD 1595.6 million by 2032, owing to the growing need for real-time monitoring and automation in hazardous zones.

• By End User (Oil & Gas, Mining, Power, Chemical & Petrochemical, Processing, and Others): The oil & gas segment is projected to reach USD 1415.6 million by 2032, due to the industry’s strict safety regulations and demand for continuous operation in explosive atmospheres.

Intrinsically Safe Equipment Market Regional Analysis

Based on region, the market has been classified into North America, Europe, Asia Pacific, Middle East & Africa, and South America.

North America accounted for a market share of around 34.09% in 2024, with a valuation of USD 1288.6 million. This dominance is driven by strict regulatory frameworks, including Occupational Safety and Health Administration and National Electrical Code standards, which mandate the use of certified equipment in hazardous locations.

The presence of mature oil & gas infrastructure, along with the high adoption of advanced automation and safety technologies, has supported market expansion. The growing deployment of rugged 5G routers in remote and hazardous industrial environments is enabling real-time data transmission and operational safety and further supporting the demand for intrinsically safe solutions in North America.

• In February 2024, Semtech Corporation launched the AirLink XR60 5G Router, an ultra-compact and rugged networking solution designed to deliver high-performance 5G and Wi-Fi 6 connectivity in space-constrained and harsh environments. The XR60 5G Router supports critical applications across public safety, utilities, smart cities, and industrial settings. It combines advanced features like 5 Gbps Ethernet, USB-C, and low-latency communication to meet the  evolving demands of edge deployments.

The market in Asia Pacific is poised to grow at a significant CAGR of 8.10% over the forecast period. The market is driven by rapid industrialization and infrastructure development. Expansion in sectors such as oil & gas, chemicals, and mining across countries like China, India, and Southeast Asia has created a high demand for explosion-proof and intrinsically safe devices.

Rising awareness about workplace safety standards and increasing foreign investment in industrial automation are also contributing to the strong growth potential for intrinsically safe equipment solutions across the region.

Regulatory Frameworks

• In the U.S., intrinsically safe equipment must comply with standards set by the National Fire Protection Association (NFPA) and the Occupational Safety and Health Administration (OSHA). The National Electrical Code (NEC) Article 500-506, outlines requirements for intrinsic safety in hazardous (classified) locations.
• In Europe, equipment used in explosive atmospheres must comply with the ATEX Directive 2014/34/EU. The regulation requires all intrinsically safe devices to be tested and certified for use in specific zones. Products must carry the CE and Ex mark and adhere to relevant EN (European Norm) standards such as the EN 60079 series.

Competitive Landscape

Key players in the intrinsically safe equipment industry are focusing on strategic initiatives to maintain and expand their market presence. Companies are heavily investing in product innovations to meet evolving safety standards and support advanced industrial automation systems.

There is a strong emphasis on developing compact, high-performance, and multi-functional devices that can operate reliably in high-risk environments. To strengthen their positions, several manufacturers are expanding their certification portfolios by aligning with international standards such as ATEX, IECEx, and NEC.

This ensures wider acceptance of their products across global markets. Strategic partnerships with industrial automation firms and system integrators are also being used to integrate intrinsically safe components into broader safety and control systems. 

• In October 2023, Bodytrak launched Bodytrak 1 IS, an intrinsically safe wearable, certified under ATEX and IECEx standards. The device is designed to support worker safety in hazardous industrial environments by delivering real-time physiological monitoring and detecting risks such as heat stress and fatigue. It aims to reduce costly medical evacuations and improve risk management.

List of Key Companies in Intrinsically Safe Equipment Market:

• Emerson Electric Co.
• Drägerwerk AG & Co. KGaA
• Rockwell Automation
• Extronics
• KROHNE
• Pepperl+Fuchs SE
• MSA
• Siemens
• Eaton
• R. STAHL AG
• Phoenix Contact
• Schneider Electric
• BARTEC Top Holding GmbH
• Honeywell International Inc.
• ABB

Recent Developments (Product Launch)

• In July 2024, Aegex Technologies, LLC launched its second-generation intrinsically safe tablet, the Aegex100M. The tablet features enhanced memory (256GB/8GB RAM), Bluetooth 5.2, Wi-Fi 6.0, an improved daylight-readable display, and an IP67 rating with IECEx certification. Designed for hazardous industrial environments, the Aegex100M supports safe operations across sectors such as oil & gas, chemical, and utilities.