When thinking about hazardous work zones, wireless load cells are actually a no-brainer. These devices offer accurate load monitoring systems while minimizing all the risks that come with wired systems.
Cutting all the cables eliminates potential ignition sources and trip hazards, while also making installation much simpler in explosive atmospheres.
They also make it easy to transmit data in real time, so you can prevent overload and get super accurate weighings even in the toughest environments.
Want to know more about the advantages of wireless load cells in hazardous work zones? Keep reading.
What are Wireless Load Cells?
Wireless load cells are force-measuring sensors that basically work just the same way as their wired counterparts, but they transmit data wirelessly instead of via a cable.
Inside, they’re using strain gauge tech to detect any deformation when the load changes, and that mechanical strain gets converted into an electrical signal which gets broadcast out to a receiver via radio frequency. That can be a wireless handheld display, a wireless receiver to a PC or a wireless receiver to a PLC.
Key Characteristics of Wireless Load Cells
- No cables in sight: This speeds up installation and makes it way safer.
- Battery powered: They often use long-lasting or replaceable lithium batteries, which keeps them running reliably.
- Available in a load of formats: There are tension links, load shackles, compression cells, load pins and crane scales available.
- Long distance transmission: Several hundred meters line-of-sight typically, but it depends on the protocol and the site conditions.
- Rugged: They often feature sealed housings and corrosion-resistant materials to keep them surviving in really harsh environments.
In hazardous environments and work zones, these load cells are often certified as intrinsically safe or explosion-proof to stop electrical energy, heat or sparks in flammable atmospheres from igniting.
What are Hazardous Work Zones?
Hazardous work zones are areas where workers face a much higher risk due to lots of different hazards. That could be physical, chemical, electrical, environmental or operational risks.
These areas require additional engineering, administrative, and procedural controls to reduce the risk of injury or damage.
Common Characteristics
Hazardous work zones often include one or more of the following:
- Explosive or flammable atmospheres: gases, vapors, or dust.
- High mechanical loads or stored energy: such as lifting, hoisting, or pressurized systems.
- Electrical hazards: high voltage, static discharge, or potential ignition sources.
- Extreme environments: heat, cold, corrosion, or moisture.
- Limited access or visibility: confined spaces, underground areas, or remote sites.
Wireless Load Cell Installations Often Happen In
- Hazardous waste and emergency response zones: Hot, warm and cold zones under HAZWOPE (Hazardous Waste Operations and Emergency Response) guidelines.
- Explosive atmosphere zones: These are areas where there’s a risk of flammable gases, vapours or dust.
- ATEX/IECEx:
- Zone 0/20: There’s a constant explosive atmosphere.
- Zone 1/21: There’s a likely one during normal ops.
- Zone 2/22: It’s unlikely or only a short time.
- CSA/North America:
- Class I, Division 1 – A flammable gas or vapour atmosphere is present continuously, frequently, or during normal operation.
- Class I, Division 2 – A flammable gas or vapour atmosphere is not likely, and if it occurs, it will be for a short time only.
- Class II, Division 1 – A combustible dust atmosphere is present continuously, frequently, or during normal operation.
- Class II, Division 2 – A combustible dust atmosphere is not likely, and if it occurs, it will be for a short time only.
- ATEX/IECEx:
- Construction and industrial sites: Temporary areas like bridges or highways with machinery hazards, suspended loads and poor visibility
Selecting the Right Wireless Load Cell System for Hazardous Zones
Before you start installing, make sure safety and regulatory compliance come first. Follow these steps:
Assess the area classification
Do a risk assessment to figure out the zone, gas/dust group, and temperature class. Then choose gear that can handle the worst-case scenario
Verify the right certifications
Check the load cell, transmitter, battery, and displays all have the right ATEX/IECEx or CSA/North America approvals. Look for things like “Ex ia IIC T4 Ga” for intrinsically safe gear in high-gas zones
Match technical specs
Look at:
- Load capacity and safety factor against the max working loads.
- Type (tension, compression etc) for the job.
- Accuracy for overload protection and critical jobs.
- Wireless loadcell range, taking into account obstacles and interference.
- IP ratings and material resistance for environmental durability.
- Evaluate the full system
Think About the Receivers, Software, Alarms, Logging, and Maintenance. Place receivers in safe zones to make compliance a whole lot easier.
Reputable companies such as Massload Technologies can be a big help with system design. They can make sure you’re meeting all the rules and regulations, and that your system is tailored to your site’s needs.
How to Install Wireless Load Cells in Hazardous Work Zones
When installing in hazardous zones, safety has to be the top priority. Installations have to follow strict protocols to prevent fires and keep workers safe.
Only people who are properly trained should attempt this, and even then, they should be doing it under a permit to work system.
Preparation and Safety Checks
Before You Start
- Check that all the certifications meet the requirements for your site.
- Do a risk assessment for the site and do some gas testing to make sure it’s safe to work in.
- Make sure you’ve got the right tools and PPE (Personal Protective Equipment) for the job, especially when working in hazardous areas.
- Thoroughly read through the manufacturer’s instructions.
Step-by-Step Installation
| Step | Action | Key Safety Notes |
| 1. Isolate the area | Stop all operations, lock out/tag out equipment, and confirm no live loads or movement. | Prevents accidental activation or load shifts during installation. |
| 2. Select mounting position | For cranes/hoists: Install as a tension link or shackle load cell between hook and load, or as a load pin in sheaves. Ensure alignment with the load axis and secure with certified shackles/bolts. | Use manufacturer-supplied hardware. Avoid twisting. |
| 3. Mechanically install the load cell | Secure the cell in place using torque settings from the manual. Check for proper seating and no binding. | Torque tools must be non-sparking if required. Inspect for damage before fitting. |
| 4. Insert approved batteries | Use only certified batteries. Install in the sealed compartment. | Never open battery cover in a live explosive atmosphere unless certified for Zone 0/1. |
| 5. Power on and pair | Activate the load cell and pair with the ATEX or CSA-certified handheld display or receiver. Test signal strength. | Perform pairing in a safe area if possible. Confirm no error codes. |
| 6. Test the system | Apply known test loads (gradually) and verify readings match calibration certificate. Check wireless range and alarms (overload warnings). | Stay outside the load path. Use secondary safety restraints (chains/slings). |
| 7. Final checks | Inspect all connections, secure covers, and label the installation. Document with photos and calibration verification. | Ensure the receiver/display is placed in a safe zone or certified hazardous area unit. |
Where to Put the Receiver/Display
Ideally, stick the receivers and interfaces in non-hazardous areas. That makes maintenance a whole lot easier and reduces the need for extra certifications. If you need to put it in a hazardous zone, make sure it’s certified.
Post-Installation Best Practices
It’s not just about installing the load cells, you’ve got to keep them running right too. Ongoing discipline is what keeps things safe and working properly:
- Regularly inspect the load cells for wear, corrosion and battery status.
- Calibrate them once a year or after any big overload or impact.
- Make sure your staff are trained to handle safe loads, alarms and protocols.
- Keep detailed records of certifications, inspections and calibrations.
Wireless load cells cut the risks of cabling and let you keep an eye on things from a distance, which makes them ideal for hazardous zones when they’re done properly.
Partner with Massload on Wireless Load Cell Solutions for Hazardous Environments
When you get wireless load cells right, they’re a safer and more efficient way to do things in hazardous high-risk areas. But you’ve got to choose and install them with care. Make sure you’re focusing on certification, thorough preparation and best practices. That’s what keeps things safe and working properly.
If you need some technical advice, or want to learn our recommended strategies to get things right and compliant, it’s always a good idea to talk to Massload’s experts and get them to help you align with your project’s needs and standards.
** Hazardous Waste Operations and Emergency Response is an OSHA standard (29 CFR 1910.120) setting rules for worker safety during hazardous substance cleanup, treatment, storage, disposal, and emergency response in the U.S.
