How Much Does It Cost to Convert a Class A Hazardous Storage Facility into a Temperature-Controlled or Explosion-Proof Cold Room?

In chemical, petrochemical, and mining operations, temperature control isn’t about freshness—it’s about safety and regulatory survival. Many Class A facilities (storing flammable liquids, electrolytes, or reactive chemicals) must maintain 20–30°C ambient conditions—or even lower for sensitive materials like lithium battery electrolytes.

But retrofitting a hazardous-area warehouse with cooling isn’t simple. Standard refrigeration can trigger explosions. So what’s the real cost? And how much product can you safely store?

📦 Storage Capacity: What Can You Actually Store?

💡 Designed for flammable solvents, battery electrolytes, peroxides, or temperature-sensitive catalysts.

💰 Total Investment: Two Scenarios Compared

✅ Option 1: Temperature-Controlled (20–30°C), Non-Explosive Zone

For general chemical storage requiring climate stability

• System: Standard industrial HVAC + dehumidification
• Total Cost: 65,000–85,000 USD
• Includes:
  • 100mm fire-rated insulation
  • Redundant cooling units (non-spark)
  • Humidity control (40–60% RH)
  • Basic monitoring with alarms

Suitable only if no explosive vapors are present (confirmed by area classification study).

✅ Option 2: Full Explosion-Proof Cold Room (ATEX / IECEx Zone 1 or 2)

For flammable liquids, battery electrolytes, or volatile organics

• System: IIB T4 certified explosion-proof refrigeration + B1 fire-resistant panels
• Total Cost: 100,000–180,000 USD
• Includes:
  • ATEX-certified compressors, fans, and electrical components
  • B1-class fire-retardant PU panels (low smoke, zero halogen)
  • Positive pressure ventilation to prevent vapor accumulation
  • Intrinsically safe control panel with remote SCADA integration
  • Emergency purge system

⚠️ Mandatory for storing Class IB/IC flammable liquids (e.g., acetone, ethanol, electrolytes) where vapors may be present.

🌍 Real-World Insight: One Petrochemical Plant, One Critical Upgrade

A battery materials supplier in Jubail Industrial City, Saudi Arabia retrofitted a 300m² Class A warehouse to store lithium hexafluorophosphate (LiPF₆) electrolyte:

• Requirement: Maintain 25°C ±2°C, <40% RH, in Zone 1 explosive atmosphere
• Solution: Full IIB T4 explosion-proof cold room
• Total Investment: $ 125,000 USD
• Result:
  • Passed Saudi Civil Defense & SASO inspection on first attempt
  • Enabled supply contract with major EV battery manufacturer
  • Avoided $ 500K+ in potential fines for non-compliant storage
  • Achieved zero thermal incidents over 18 months

“This wasn’t a cooling project—it was a license to operate.”
— EHS Manager, Gulf Advanced Chemicals