In explosion-prone areas, spark-free hammers and mallets are essential to ensure the safety of people and the environment. There are numerous manufacturers on the market that specialize in the production of these special tools. But what should you consider when making a selection? This guide will help you make the right decision quickly and save time effectively.
Why spark-free hammers are indispensable in Ex areas
In refineries, chemical plants, the oil and gas industry, as well as in mining, explosive gases or dusts are not uncommon. Just a single spark can have catastrophic consequences. Spark-free hammers are therefore made from special copper alloys that are softer than conventional steel tools, thereby minimizing the risk of spark generation.
Important: The use of spark-free tools is just one of several protective measures in explosive areas. Additional safety precautions according to the regulations of the professional associations must be strictly adhered to.
Materials of Spark-Free Hammers in Comparison
Depending on Application, security requirements, and budget various material options are available.
| Material | Properties | Advantages | Disadvantages |
|---|---|---|---|
| Aluminum-Copper (AlCu) | Medium hardness, low spark | Affordable, durable | Lower wear resistance than BeCu |
| Beryllium-Copper (BeCu) | High hardness, extremely spark-free | Longer lifespan, more durable | Expensive, beryllium dust is harmful to health when machining |
| Special bronze | Softer than BeCu, good spark resistance | Classic material for Ex-tools, proven | Not as durable as BeCu |
The right choice: Which material for which application?
1. Aluminum-Copper Hammers – The Affordable Alternative
Aluminum-copper alloys are a cost-effective choice for simple applications where high spark resistance is not strictly necessary. They are commonly used for less demanding tools such as wrenches and chisels, but can also be used for lighter hammers.
Suitable for:
✔ General Maintenance Work
✔ Occasional applications in Ex areas
✔ Users with a limited budget
Not ideal for:
✘ High-load tools with strong mechanical stress
✘ Long-term use in extreme environments
2. Beryllium-Copper Hammers – Maximum Safety and Durability
Beryllium-Copper (BeCu) is the most efficient alloy for spark-free tools. It combines high strength, durability, and nearly complete spark-free properties. Especially in safety-critical explosive areas, BeCu is often the preferred choice.
Suitable for:
✔ Intensive operations in explosion-prone areas
✔ Mechanics, engineers, and maintenance teams in the petrochemical and chemical industries
✔ Work with high mechanical wear
Important safety information:
When working with beryllium copper (e.g., grinding or drilling), beryllium particles are generated that are highly toxic and potentially carcinogenic. Therefore, appropriate ventilation and protective measures are essential.
3. Special Bronze Hammers – The Proven Classic
Hammers made of special bronze are widely used and are often employed for locksmith hammers, sledgehammers, claw hammers, or hatchets. The handle is usually made of hickory wood for high shock absorption. Alternatively, there are variants with fiberglass handles for added durability.
Suitable for:
✔ General Work in Ex-Zones
✔ Entry-level solutions for explosion-proof tools
✔ Users seeking a balanced price-performance ratio
Not ideal for:
✘ High-intensity stress (BeCu is better suited here)
Additional selection criteria for the right ex-hammer
In addition to the material, there are other important factors to consider when selecting a spark-free hammer:
✅ Certification & Standards – Check ATEX, IECEx, or local safety regulations
✅ Weight & Ergonomics – Finding the right balance between impact power and handling
✅ Handle material – Hickory wood for natural cushioning, fiberglass for greater durability
✅ Application area – Is the tool certified for Zone 1/21 or Zone 2/22?
Conclusion: Which spark-free hammer is the best choice?
💡 If safety comes first: Beryllium copper offers the highest spark resistance and durability, but it is more expensive and requires special precautions when machining.
💡 If the budget is limited: Aluminum-copper is a good choice for lighter work, but it is less durable than BeCu or special bronze.
💡 If a proven standard model is desired: special bronze offers a solid balance of safety, cost, and durability and is a frequently chosen solution.
Whichever option you choose: The right choice depends on your specific area of application.
📢 Non-sparking tools are available here at ATEXshop.de. Get informed now!