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Lockout Tagout Guide
Lockout Tagout (LOTO) Guide: Equipment, Kits & Australian WHS Compliance
What Is Lockout Tagout (LOTO)?
Lockout Tagout — commonly abbreviated as LOTO — is a personal isolation system used before carrying out any maintenance, repair, cleaning, or adjustment work on plant or equipment. The purpose is to ensure that the energy sources powering that equipment are completely isolated, and that no-one other than you can re-energise it while you are working on it.
The key word is personal. Standard isolation — switching a machine off at the control panel or closing a valve — is not LOTO. LOTO means applying your own padlock with your own key to the physical isolation point, so that the machine cannot be started by anyone else while you are exposed to it. LOTO padlocks are deliberately built for visibility and one-person-one-key isolation rather than maximum cut resistance — they are not the same product as security padlocks used for asset protection, which prioritise cut resistance, pick resistance and weatherproofing (see the Industrial Padlock Guide for the security padlock side, including CEN BS EN 12320 grades, body and shackle types, and smart padlocks for mining/utility infrastructure).
LOTO is required any time a worker could be injured by the unexpected release of hazardous energy — including electrical energy, mechanical movement, hydraulic or pneumatic pressure, thermal energy, and stored energy such as springs under tension, capacitors, or elevated loads.
When LOTO is done correctly, the only way to restore energy is for every worker involved to remove their own lock. No supervisor can override it. No master key exists. That is the whole point.
Lockout/Tagout (LOTO) — Quick Reference (AS/NZS 4836)
LOTO isolates energy sources during maintenance + service to prevent unexpected start-up. AS/NZS 4836:2023 governs procedures. The mandatory 6-step LOTO sequence below is the foundation of every AU industrial maintenance program.
| Step | Action | Purpose |
|---|---|---|
| 1. Prepare | Identify all energy sources (electrical, hydraulic, pneumatic, stored) | Plan isolation before touching equipment |
| 2. Shut Down | Stop equipment using normal controls | Controlled shutdown reduces risk |
| 3. Isolate | Operate isolating device (breaker, valve, plug) | Physically disconnect energy source |
| 4. Lock + Tag | Apply personal padlock + danger tag to each isolation point | Prevent re-energising; tag identifies worker |
| 5. Dissipate Stored Energy | Bleed pressure, discharge capacitors, lower loads, block rams | Eliminate residual + stored hazards |
| 6. Verify Isolation | Test for absence of energy (try-to-start, voltage test) | Confirm equipment is truly safe before work |
Critical: Personal danger tags + lockout locks are NEVER removed by anyone except the person who applied them — AS/NZS 4836 mandate. Group lockout for multi-worker tasks uses a group lockout box. Test + tag electrical equipment per AS/NZS 3760. AIMS stocks lockout kits, group lockout boxes, padlocks, safety tags + signs + safety equipment.
The Law: What Australian Workplaces Are Required to Do
Lockout Tagout is not simply best practice in Australia — it is a legal requirement under Work Health and Safety legislation.
WHS Act and Model WHS Regulations
The Work Health and Safety Act 2011 and the Model WHS Regulations are harmonised across New South Wales, Queensland, South Australia, the ACT, Tasmania, the Northern Territory, and the Commonwealth. Western Australia harmonised under its own Work Health and Safety Act 2020 from 2022. Victoria operates under the Occupational Health and Safety Act 2004 with different but equivalent obligations.
Under the Model WHS Regulations, Regulations 208–215 deal specifically with the management of plant in the workplace. Regulation 208 requires that plant which could cause injury through unexpected start-up or release of stored energy must be able to be isolated from all energy sources. Regulation 210 requires that a person conducting a business or undertaking (PCBU) must ensure risks associated with plant are eliminated or minimised — which in practice means providing a documented isolation and lockout system.
Codes of Practice
Safe Work Australia's Code of Practice: Managing Risks of Plant in the Workplace provides detailed practical guidance on isolation requirements, including the use of lockout devices, tags, and isolation registers. While codes of practice are not law, they represent the accepted means of achieving compliance — and a regulator will reference them during an audit or investigation.
Australian Standards
- AS/NZS 4836:2011 — Safe working on or near low-voltage electrical installations. Specifies isolation, testing, and lockout requirements for electrical work.
- AS 4024.1603-2006 — Safety of machinery: Design of controls, interlocks and guarding. Addresses prevention of unexpected start-up and the role of lockable isolation devices on machinery.
Consequences of Non-Compliance
Regulators including SafeWork NSW, WorkSafe Victoria, and their state equivalents actively investigate and prosecute LOTO failures. Fines for PCBUs can reach into the hundreds of thousands of dollars. Where a worker is killed or seriously injured due to inadequate isolation, prosecution under reckless endangerment provisions carries the possibility of imprisonment. The cost of a properly stocked lockout station is trivial by comparison.
The 6 Types of Hazardous Energy
One of the most common LOTO failures is isolating only the obvious energy source — usually electricity — while overlooking others. A machine may have multiple simultaneous energy sources, all of which must be isolated before work begins.
| Energy Type | Examples | Isolation Method | LOTO Device Required |
|---|---|---|---|
| Electrical | Motors, control panels, switchboards, lighting circuits | Switch off at isolator, circuit breaker, or disconnect switch | Circuit breaker lockout, isolator lockout, plug lockout |
| Mechanical (kinetic) | Rotating shafts, flywheels, conveyor belts, fans coasting to a stop | Lock out electrical drive; wait for full stop; block if needed | Padlock on electrical isolator; mechanical blocking device |
| Hydraulic | Hydraulic presses, lifts, cylinders, clamping fixtures | Close and lock supply/return valves; bleed pressure to zero | Ball valve lockout, gate valve lockout; pressure must be confirmed at zero |
| Pneumatic | Pneumatic actuators, cylinders, air-powered tools, brakes | Close and lock air supply valve; bleed downstream lines to atmosphere | Ball valve lockout, butterfly valve lockout |
| Thermal | Steam lines, hot surfaces, ovens, furnaces, heated platens | Isolate steam/heat source; allow equipment to cool to safe temperature | Valve lockout on steam isolation valve; permit-to-work if cooling time is extended |
| Stored / Potential | Compressed springs, capacitors, elevated loads, charged hydraulic accumulators, gravity-held dies | Release, restrain, block, or discharge — see Stored Energy section below | Physical restraint devices (blocks, props, chains); this is an action, not just a lock |
Always conduct a full energy survey of any plant before establishing a LOTO procedure. For complex machines, this survey should be documented in an isolation register or machine-specific LOTO procedure card that lists every isolation point, its location, and the device required.
Lockout vs Tagout: Understanding the Critical Difference
These two terms are often used together, but they are not the same thing — and confusing them can have fatal consequences.
Lockout
A lockout device is a physical device that prevents an isolation point from being operated while it is applied. A padlock through an isolator hasp physically prevents the switch from being turned on. A circuit breaker lockout clip physically prevents the breaker from being reset. The isolation cannot be defeated without cutting the lock — an action that is both visible and a serious safety violation.
Tagout
A tag is an information device. It communicates who has applied the isolation, why, and when. Tags are attached alongside locks. They do not prevent re-energisation on their own — they can be removed, torn, or ignored. A tag says "do not operate." A padlock enforces it.
Can You Use a Tag Without a Lock?
Under Australian WHS legislation and AS/NZS 4836, tagout-only (without a physical lock) is only acceptable when the isolation point physically cannot accommodate a lockout device and there is genuinely no practical alternative. This is extremely rare with modern equipment, which is designed to be lockable. In practice: always lock, always tag. A tag alone is not isolation.
The "I've tagged it off" assumption is one of the most dangerous habits in Australian workplaces. Tags are supplementary information — not a substitute for physical lockout.
The LOTO Procedure: 7 Steps
The following procedure applies to standard lockout tagout for a single worker. Multi-worker situations require additional steps — see the hasp and group lockout sections below.
Step 1: Notify
Inform all affected workers, supervisors, and operators that the equipment is about to be isolated for maintenance. Ensure no-one is in the process of operating or depending on the equipment.
Step 2: Identify All Energy Sources
Refer to the machine's isolation register or LOTO procedure card. Identify every energy source: electrical supply, hydraulic lines, pneumatic connections, thermal inputs, and any stored energy. Do not proceed until all sources are identified.
Step 3: Shut Down the Equipment
Turn off the equipment using its normal controls — stop buttons, control panels, or operating switches. This is not isolation; it is controlled shutdown before isolation.
Step 4: Isolate Each Energy Source
Operate every isolation device: switch off the isolator or circuit breaker, close valves, disconnect from the energy supply. Each isolation device must be moved to its OFF or CLOSED position.
Step 5: Apply Your Padlock and Tag
Apply your personal padlock to each isolation point. If the isolation point cannot accommodate a padlock directly, use a hasp first, then apply your padlock to the hasp. Attach your lockout tag alongside each padlock — complete all required fields (name, date, time, reason, contact).
Step 6: Release Stored Energy
This is the step most often skipped — and the one that causes injuries even when all other steps have been followed correctly. Before working on the equipment, you must actively address all stored energy. Bleed pneumatic lines to atmosphere. Release hydraulic pressure through bleed points. Block elevated loads with physical supports — never rely on hydraulic or pneumatic cylinders to hold a load after isolation. Allow capacitors time to discharge (confirm with test equipment). Restrain springs mechanically before working near them.
Step 7: Verify Isolation
Confirm the equipment is truly isolated before starting work. For electrical isolation: use a calibrated voltage tester to confirm the circuit is dead at the work point. For mechanical isolation: attempt to start the equipment using its normal controls (it should not respond). For hydraulic/pneumatic: check that pressure gauges read zero. Never assume isolation is complete — always verify.
Restoring Energy After Work
When work is complete: remove all tools and personnel from the machine, ensure all guards are reinstated, and then — and only then — remove your padlock and tag. Energy should be restored in the reverse order of isolation. Notify all affected workers that the equipment is being returned to service.
LOTO Equipment Guide
Selecting the right LOTO hardware is where most workplaces make mistakes — either by under-equipping (one shared padlock for a team) or by buying generic equipment that doesn't suit the specific isolation points on their plant. Here is what each piece of equipment does and how to choose it.
Safety Padlocks
A LOTO padlock is not an ordinary padlock. It is specifically designed for isolation work with features that standard padlocks do not have:
- Narrow shackle diameter — typically 6mm, to fit through standard hasp eyelets and isolation device holes
- Safety colours — bright red, yellow, blue, green, or orange for instant visual identification at a distance
- Unique key per lock — each padlock comes with its own unique key set. No master key. No supervisor key.
- Non-conductive body options — nylon or composite body padlocks for electrical work where metal contact is a risk
- Durable construction — industrial-grade, resistant to cutting and corrosion
AIMS Industrial stocks Brady and Masterlock safety padlocks — both are the internationally recognised standards for LOTO programs. Brady's SafeLock series and Masterlock's 406/410 series (nylon body, 38mm) are the most widely used in Australian industrial workplaces.
Browse LOTO padlocks at AIMS Industrial →
Keyed-Alike vs Keyed-Different: The Decision That Confuses Everyone
For the full discussion of keyed-alike, keyed-different and master-keyed systems across BOTH safety (LOTO) and asset-security contexts — including the one-person-one-key rule, fleet/multi-site KA patterns, and mining-site master-keyed hierarchies — see the keying systems section of the Industrial Padlock Guide.
This is the most common source of confusion when setting up a LOTO program — and getting it wrong can either undermine safety or create an impractical kit. Here is the clear distinction:
| Option | What It Means | When to Use It |
|---|---|---|
| Keyed-Different (KD) | Every padlock has its own unique key. Lock A cannot be opened by Lock B's key. | Standard choice for personal LOTO packs. One worker = one lock = one key. Nobody else can open your lock. |
| Keyed-Alike (KA) | All padlocks in the set open with the same key. One worker carries one key that opens all their own locks. | For a single worker who needs to apply multiple padlocks to multiple isolation points on the same machine — one key opens all their own locks. |
The critical rule: Keyed-alike sets are for one worker with multiple isolation points — not for multiple workers sharing keys. A team of five workers on the same machine should each have their own keyed-different padlock. If you issue keyed-alike locks to a team so the supervisor can open anyone's lock, you have nullified the entire safety principle of LOTO.
Practical example: A maintenance electrician routinely isolates three separate distribution boards before working on a machine. They carry three keyed-alike padlocks — one key opens all three. Their locks are keyed-different from every other worker's locks. This is correct LOTO practice.
Lockout Hasps
A lockout hasp is a multi-hole device that fits through an isolation point, allowing multiple padlocks to be applied simultaneously. The hasp itself locks the isolation point in the OFF position; each worker then applies their own padlock to one of the hasp's holes. The isolation point cannot be restored until every padlock is removed — meaning every worker must have finished and cleared the machine before energy can be restored.
Hasps are essential any time more than one worker will be on the same machine at the same time. The number of holes in the hasp determines how many workers can lock out simultaneously:
| Hasp Type | Padlock Positions | Typical Use |
|---|---|---|
| 3-hole hasp | Up to 3 workers | Small maintenance teams, two-trade work (e.g., electrician + fitter) |
| 6-hole hasp | Up to 6 workers | Standard for medium production environments |
| 12-hole hasp | Up to 12 workers | Large shutdowns, major maintenance teams |
Both Brady and Masterlock supply aluminium safety hasps in 3-hole, 6-hole, and 12-hole configurations. Aluminium is preferred for electrical work (non-magnetic, lower conductivity risk).
Lockout Tags
Tags are applied alongside every padlock. Even when a padlock physically prevents re-energisation, the tag communicates vital information to others in the workplace. Australian-compliant lockout tags must include:
- The worker's full name
- Date and time of application
- Reason for isolation (e.g., "Replacing motor coupling — do not operate")
- Contact number
- Clear "DANGER — Do Not Operate" or equivalent safety warning
Brady tags are the industry standard in Australia and come in three classifications:
- DANGER tags — red/black, for active isolation where equipment must not be operated
- WARNING tags — orange/black, for caution situations where extra care is required
- OUT OF SERVICE tags — not a LOTO tag — used for defective equipment awaiting repair, not for active isolation
Tags must be durable enough to remain legible in the working environment. Brady's lockout tags are UV-resistant, weather-resistant, and rated for industrial conditions. Never use paper labels or cable ties with handwritten notes as LOTO tags.
Lockout Stations
A lockout station is a wall-mounted board or cabinet that stores all LOTO equipment for a specific work area. Stations serve two purposes: ensuring that equipment is always available when needed, and making compliance visible — a well-stocked, maintained station signals that LOTO is taken seriously in the workplace.
Sizing a lockout station correctly:
| Station Size | Workers Served | Typical Contents |
|---|---|---|
| Small shadow board | 3–6 workers | 5–8 padlocks, 20 tags, 2 hasps, 1 MCB lockout, 1 valve lockout |
| Medium open board | 7–15 workers | 10–15 padlocks, 50 tags, 4 hasps, MCB/MCCB lockout set, 2 valve lockouts, cable lockout |
| Large cabinet (filled) | 16–30+ workers | 20+ padlocks, 100+ tags, 6+ hasps, full circuit breaker kit, full valve kit, cable lockout, group lockout box |
Brady and Masterlock both supply filled stations (padlocks and devices pre-installed) and unfilled stations (for workplaces that want to build a custom kit). For most Australian industrial workplaces, a pre-filled medium station covers the majority of isolation scenarios.
Circuit Breaker Lockouts
Circuit breaker lockouts clip or clamp onto a circuit breaker toggle or rotary isolator, physically preventing it from being switched to the ON position. Unlike an open switchboard which can be simply switched back on, a circuit breaker with a lockout device can only be restored after the device — and the padlock through it — is removed.
Selecting the correct device depends on your switchboard:
| Device Type | Application | Notes |
|---|---|---|
| MCB lockout (toggle type) | Standard 1-pole or 2-pole miniature circuit breakers | Clips over the toggle. Check fit against your specific MCB brand. |
| MCCB lockout | Larger 3-pole moulded case circuit breakers (industrial switchboards) | Bolt-on or clip-on; must match the MCCB make and model |
| Rotary isolator lockout | Rotary disconnect isolators (very common in Australian industrial panels) | Attaches to the isolator shaft; hasp holes allow multiple padlocks |
| Multi-pole lockout | Locking out 2–4 poles simultaneously on multi-pole MCBs | Prevents individual poles being switched independently |
| Plug lockout | Portable equipment with 3-pin or 3-phase plugs | Locks the plug into a plastic housing that cannot be inserted |
Both Brady and Masterlock manufacture circuit breaker lockout kits for Australian switchboards. If you are unsure which device suits your installation, bring your circuit breaker make/model details when ordering — the fit must be confirmed before use.
Valve Lockouts
Valve lockouts clamp onto manual isolation valves, preventing them from being opened or closed once the lockout is applied and padlocked. They are essential for isolating pneumatic, hydraulic, steam, chemical, and water energy sources.
| Valve Type | Lockout Device | Typical Application |
|---|---|---|
| Ball valve (lever handle) | Ball valve lockout — clamps over handle, locked in closed position | Air lines, water supply, hydraulic supply, chemical lines |
| Gate valve (handwheel) | Gate valve lockout — fits over handwheel and spindle | Water mains, larger-diameter industrial pipework |
| Butterfly valve | Butterfly valve lockout — clamps over the disc operator lever | Large-bore process valves, HVAC isolation |
| Non-standard / unknown valves | Universal adjustable valve lockout or cable lockout | Where no specific device fits the valve type |
Ball valve lockouts come in size ranges — always confirm the valve body size (typically 1/4" to 4" for standard industrial ball valves) before ordering. Brady and Masterlock both offer ball valve lockouts in multiple size configurations.
Cable Lockouts
A cable lockout is a flexible stainless steel cable threaded through an isolation point and looped back through a padlock. It is the universal tool when no specific lockout device fits the isolation point — unusual switch configurations, non-standard valve handles, push-button panels with locking provisions, or any irregular geometry that standard devices cannot accommodate.
Brady's Universal Cable Lockout is the standard choice for Australian workplaces. The cable can be looped through multiple points simultaneously, making it useful for securing multiple small switches or isolation points on a single cable run.
Group Lockout Boxes
A group lockout box is used when a machine has a large number of individual isolation points — too many to attach a hasp to each. The procedure works as follows: a single lock (the "system lock") is applied to each isolation point on the machine. The key to that system lock is placed inside the group lockout box. The box is then treated like any other isolation point — each worker in the team applies their personal padlock to the box. No-one can access the isolation keys until the last worker removes their padlock.
Group lockout boxes are most appropriate for complex production machinery, large plant with 10 or more isolation points, and environments with formal permit-to-work systems. They add administrative complexity — each use requires clear documentation of which keys are inside — but they are the most practical solution for machines that would otherwise require each worker to hasp every isolation point independently.
The One-Lock, One-Key Rule
This is the foundational principle of LOTO, and it is non-negotiable:
Your padlock. Your key. No exceptions.
Every worker who could be exposed to the hazard applies their own padlock. They are the only person who holds a key to that lock. No supervisor has a spare. No safety manager has a master key. No "emergency override" procedure exists that bypasses this rule — because the moment a master key exists, the protection the system provides is gone.
Common Scenarios and How to Handle Them
| Situation | Correct Response |
|---|---|
| Worker finishes their shift and goes home, leaving their lock on | Document the situation. Contact the worker. If the lock must be removed (genuine emergency), this requires documented management authorisation and a witnessed cutting of the lock — never a spare key. |
| Contractor on site needs to work on isolated equipment | The contractor applies their own padlock to the hasp alongside the in-house team's locks. Contractors must have their own LOTO equipment. |
| New employee doesn't have their own padlock yet | They do not work on isolated plant until equipped. Lending them someone else's padlock defeats the principle — they cannot hold the only key to someone else's lock. |
| Supervisor wants to verify the work is done and re-energise for testing | All workers must remove their own locks first. The supervisor cannot remove a worker's lock without that worker's knowledge and presence. |
Department Keying Systems
Where a department has many workers performing LOTO regularly, it is common to issue each worker a personal padlock (keyed-different from all other workers) and provide them with additional keyed-alike spares for multi-point isolations. The department's padlocks are all keyed-different from each other — so no worker's key opens any other worker's lock — while each individual worker can carry 2–3 locks that all share their own unique key. This is both practical and compliant.
Stored Energy: The Step That Gets People Killed
Stored energy is the most frequently overlooked element of LOTO. A machine that has been correctly locked out from all active energy sources can still seriously injure or kill a worker if stored energy is not addressed before work begins.
The isolation locks prevent the machine from being re-energised. They do not discharge or restrain energy that is already present in the system.
Types of Stored Energy and How to Address Them
| Stored Energy Type | Example | What to Do Before Working |
|---|---|---|
| Pneumatic pressure | Air in downstream lines after isolating the air supply valve | Open bleed points or drain valves to release pressure to atmosphere. Confirm gauges read zero. Lines can still contain compressed air even after valve closure. |
| Hydraulic pressure | Hydraulic oil under pressure in a cylinder or accumulator | Release pressure through bleed points or relief valves. Confirm pressure gauges read zero. Hydraulic accumulators retain pressure even after pump shutdown — always bleed and confirm. |
| Elevated loads (gravitational) | A hydraulically held press die, a suspended conveyor section, a ram held by pneumatic pressure | Block or prop the load with physical mechanical supports before working beneath or near it. Never rely on hydraulic or pneumatic cylinders to hold a load after the system has been isolated — they can drift. |
| Compressed springs | Springs in clutches, brakes, dies, or spring-return mechanisms | Mechanically restrain or release the spring before working near it. Never remove fasteners from spring-loaded assemblies without first restraining the spring. |
| Capacitors (electrical) | Capacitors in VFD (variable frequency drive) DC bus, power factor correction banks, large motor starters | Allow minimum discharge time (typically 5–10 minutes for VFDs — check manufacturer data). Confirm voltage is near zero at the capacitor terminals using a calibrated meter before touching internal components. |
| Thermal energy | Hot surfaces on ovens, heat exchangers, hydraulic oil systems running at high temperature | Allow equipment to cool to a safe working temperature. Do not rely on insulation to protect — measure surface temperature before contact. |
| Chemical (stored pressure) | Process lines containing pressurised chemicals or gases | Depressurise, isolate, and purge lines before opening. This typically requires a permit-to-work in addition to LOTO. |
The stored energy step must be completed and verified before any worker begins work — not assumed based on the isolation alone.
LOTO Kit Selection Guide
The right LOTO kit depends on the size of your workplace, the types of energy present, and the number of workers who may work on isolated plant simultaneously. This guide covers the most common Australian scenarios.
| Workplace Type | Workers on Plant | Minimum Kit Requirements |
|---|---|---|
|
Small workshop / trade (fabrication, HVAC, electrical contractor) |
1–3 | 1 personal LOTO pack per worker: safety padlock (KD), 10 tags, 1 × 3-hole hasp, 1 × MCB lockout, 1 × ball valve lockout |
|
Medium workshop / maintenance team (manufacturing, food processing, utilities) |
4–10 | 1 padlock per worker (KD) + 2 spare padlocks, 50 tags, 2 × 6-hole hasps, MCB/MCCB lockout kit, 2 × ball valve lockouts, 1 × cable lockout, small lockout station |
|
Large production facility (heavy manufacturing, mining, chemicals) |
10–25+ | Full lockout station (15–20+ padlocks), 100+ tags, 6-hole and 12-hole hasps, full circuit breaker lockout kit (MCB/MCCB/rotary), full valve kit (ball/gate/butterfly), cable lockout, group lockout box, isolation register for each machine |
| Contractor or mobile worker | 1 (on client sites) | Personal LOTO bag: 2 safety padlocks (KD), 1 × 3-hole hasp, 10 tags, universal cable lockout, MCB lockout — self-sufficient on any client site |
For workplaces with significant hydraulic, pneumatic, or steam systems, supplement the above with the appropriate valve lockout types listed in the equipment section. When in doubt, a site walk with LOTO equipment in hand — identifying every isolation point on every piece of plant — is the most reliable way to determine what hardware you actually need.
Browse the full LOTO equipment range at AIMS Industrial →
What a SafeWork Audit Checks For
If a regulator visits your site following an incident — or on a proactive inspection — these are the areas they will examine in relation to LOTO compliance:
| Audit Item | What the Inspector Looks For |
|---|---|
| Written LOTO procedure | A documented isolation procedure specific to your workplace, accessible to all workers who may perform maintenance |
| Isolation point labelling | Every isolation point on all plant is clearly identified — labels, tags, or engraved plates showing what the isolator controls and how to operate it |
| Personal padlock provision | Each worker who performs LOTO has their own padlock with a unique key that they personally control |
| Equipment availability | LOTO devices (hasps, valve lockouts, circuit breaker lockouts) are available, in good condition, and accessible at the point of use |
| Worker training records | Evidence that all workers who perform LOTO have been trained in the procedure. Training does not need to be a formal accredited course but must be documented and site-specific. |
| Contractor management | Contractors working on your plant are covered by your LOTO procedure or bring their own documented equivalent. The PCBU remains responsible for contractor safety on site. |
| Isolation register / LOTO cards | For complex machinery, a machine-specific isolation procedure card listing every energy source and the required lockout device for each |
| Post-incident review | Evidence that LOTO procedures were reviewed after any near-miss or incident involving plant isolation |
The most common finding in SafeWork investigations involving LOTO failure is not the absence of a policy — it is that workers did not have the equipment to follow it. A LOTO policy that requires personal padlocks but provides only a single shared padlock at the machine is not compliance. Equipping every worker with their own kit is the foundation.
LOTO Equipment at AIMS Industrial
AIMS Industrial stocks a full range of Brady and Masterlock lockout tagout equipment for Australian workplaces — from individual personal packs to complete filled lockout stations. The range covers padlocks (keyed-different and keyed-alike sets), multi-lock hasps, lockout tags, lockout stations, MCB/MCCB/rotary isolator lockouts, ball valve and gate valve lockouts, butterfly valve lockouts, cable lockouts, and group lockout boxes.
LOTO Equipment at AIMS Industrial
Your one-stop shop for Brady & Masterlock LOTO equipment
AIMS Industrial stocks a full range of Brady and Masterlock lockout tagout equipment for Australian workplaces — from individual personal packs to complete filled lockout stations. The range covers padlocks (keyed-different and keyed-alike sets), multi-lock hasps, lockout tags, lockout stations, MCB/MCCB/rotary isolator lockouts, ball valve and gate valve lockouts, butterfly valve lockouts, cable lockouts, and group lockout boxes.
Frequently Asked Questions: Lockout Tagout
What is lockout tagout (LOTO)?
Lockout Tagout (LOTO) is a personal isolation system used before performing maintenance, repair, or cleaning work on plant or equipment. A worker applies their own padlock to each energy isolation point on the machine, ensuring that the energy source cannot be restored by anyone else while they are working. A tag is attached alongside each padlock to communicate who has applied the isolation, why, and when. LOTO protects workers from the unexpected release of hazardous energy — electrical, mechanical, hydraulic, pneumatic, thermal, and stored.
Is lockout tagout required by law in Australia?
Yes. Under the Model WHS Regulations (Regulations 208–215), PCBUs (persons conducting a business or undertaking) are required to ensure that plant which could cause injury through unexpected start-up or release of stored energy can be isolated from all energy sources, and that appropriate controls — including physical lockout devices — are in place. AS/NZS 4836:2011 and AS 4024.1603-2006 provide the technical standards for electrical and machinery isolation respectively. SafeWork and equivalent state regulators actively prosecute LOTO failures, particularly where workers have been injured or killed.
What is the difference between lockout and tagout?
A lockout device physically prevents an isolation point from being operated — it cannot be restored without removing the padlock. A tag is an information device that communicates who applied the isolation, when, and why. Tags do not physically prevent re-energisation. Under Australian WHS standards, locks and tags are used together — the lock prevents unauthorised re-energisation, and the tag communicates the reason and owner of the isolation. A tag alone is not isolation.
Can I use a tag instead of a padlock to isolate equipment?
In Australian workplaces, tagout-only (without a physical lock) is only acceptable when the isolation point physically cannot accommodate a lockout device — which is extremely rare with modern plant. In practice, you should always use a padlock plus a tag. Tags can be torn off, ignored, or removed without being noticed. A padlock cannot. The WHS Code of Practice on Managing Risks of Plant in the Workplace makes clear that physical lockout is the required control where it is practicable — which it is in almost every situation.
Does every worker need their own padlock?
Yes. Each worker who could be exposed to a hazard from the plant must apply their own personal padlock to the isolation point (or to a hasp where multiple workers are present). This is the fundamental principle of LOTO — your padlock, your key, your protection. No supervisor can hold a spare key. No master key should exist. If only one padlock is used and shared, the system provides no protection to any worker beyond the one who applied it.
What does "keyed alike" mean for LOTO padlocks, and when should I use it?
A keyed-alike (KA) set means that all padlocks in the set open with the same key. This is intended for a single worker who needs to apply multiple locks to multiple isolation points on the same machine — they carry one key that opens all their own locks. Keyed-alike is not for teams: you should never issue keyed-alike padlocks to a group of workers so that they can open each other's locks — this defeats the purpose of LOTO. The standard choice for personal LOTO packs is keyed-different (KD), where each padlock has its own unique key.
What is a lockout hasp and when do I need one?
A lockout hasp is a multi-hole device that fits through an isolation point and allows multiple workers to each apply their own padlock. The isolation point cannot be restored until every padlock has been removed — ensuring every worker has cleared the machine. Hasps are required any time more than one person is working on the same isolated machine simultaneously. They come in 3-hole, 6-hole, and 12-hole sizes depending on the maximum number of workers likely to be on the machine at once.
How do I lock out a circuit breaker or isolator switch?
Use a circuit breaker lockout device specific to the type of breaker: MCB lockout clips for standard miniature circuit breakers, MCCB lockouts for industrial moulded case circuit breakers, and rotary isolator lockouts for rotary disconnect switches. The device clips or bolts onto the breaker, preventing it from being switched to the ON position. Your padlock is then applied through the lockout device's hasp hole. For multi-pole breakers, ensure the lockout device covers all poles. Brady and Masterlock both manufacture AU-compatible circuit breaker lockout kits — match the device to your specific breaker make and model before purchasing.
How do I lock out a ball valve or pneumatic line?
Close the ball valve to the OFF position, then apply a ball valve lockout device over the valve handle to prevent rotation. The lockout device has a hasp hole for your padlock. After locking the valve, bleed the downstream line to atmosphere to release residual pressure — do not assume the line is at zero pressure just because the valve is closed. Ball valve lockouts come in size ranges (1/4" to 4" and larger); confirm your valve body size when ordering. For gate valves and butterfly valves, specific lockout devices are available. Where the valve type is non-standard, a cable lockout threaded through the valve handle is the alternative.
What is stored energy and why do I need to address it before working?
Stored energy is energy that remains in a machine or system even after it has been isolated and locked out from its active energy sources. Types include pneumatic pressure in downstream lines, hydraulic pressure in cylinders and accumulators, elevated loads held by hydraulic or pneumatic systems, springs under compression or tension, capacitors in VFDs and motor starters that retain a DC charge, and thermal energy in hot components. Stored energy has killed workers who followed all other LOTO steps correctly. After applying isolation locks, you must actively release, restrain, block, or discharge all stored energy before starting work.
What information must be on a lockout tag under Australian law?
While specific tag format requirements vary by state and industry, Australian LOTO best practice (aligned with the WHS Code of Practice) requires tags to include: the worker's full name, the date and time the tag was applied, the reason for isolation, a contact number, and a clear "DANGER — Do Not Operate" or equivalent warning. Tags must be durable enough to remain legible in the working environment. Brady lockout tags are designed for industrial conditions and comply with Australian workplace safety requirements.
Can a supervisor or manager remove a worker's lockout padlock?
No. The fundamental rule of LOTO is that only the person who applied the padlock removes it. No supervisor, manager, or safety officer should ever remove another worker's padlock — doing so eliminates the protection the system provides. If a worker leaves site with their lock still applied (an emergency situation), the documented response is to attempt to contact the worker, obtain management authorisation, and cut the lock in the presence of a witness — never to use a spare key, because no spare key should exist.
How many padlocks and lockout devices do I need for my workplace?
At minimum, every worker who performs maintenance on plant needs their own padlock with their own key. Beyond that, the number of hasps, valve lockouts, and circuit breaker lockouts depends on the number and types of isolation points on your plant. The most reliable approach is to conduct a site walk and list every piece of plant, every isolation point, and the type of lockout device each requires. For most medium Australian workshops, a medium lockout station pre-filled with 10–15 padlocks, 4 hasps, an MCB/MCCB kit, and valve lockouts covers the majority of scenarios.
What is a group lockout box and when do I use one?
A group lockout box is used for complex machines with many individual isolation points. A single system lock is applied to each isolation point and its key is placed in the group box. Each worker then applies their personal padlock to the group box rather than to each individual isolation point. The box cannot be opened until every worker removes their padlock. Group lockout boxes are most appropriate for large production machinery with 10 or more isolation points, or environments with formal permit-to-work systems where documenting which keys are inside the box is practical to manage.
What Australian standards apply to lockout tagout?
The primary Australian standards governing LOTO are AS/NZS 4836:2011 (Safe working on or near low-voltage electrical installations and equipment) and AS 4024.1603-2006 (Safety of machinery: Design of controls, interlocks and guarding — Prevention of unexpected start-up). These sit within the broader WHS regulatory framework: the Model WHS Regulations (particularly Regulations 208–215 on plant isolation) and the Safe Work Australia Code of Practice: Managing Risks of Plant in the Workplace. Western Australia and Victoria have their own WHS legislation but apply equivalent isolation requirements.
Do I need to provide LOTO training to my workers?
Yes. Under WHS regulations, PCBUs must ensure workers are trained in safe work procedures, which includes LOTO. There is no nationally accredited LOTO training course in Australia — training can be delivered in-house by a competent person, provided it covers the specific procedures, equipment, and isolation points relevant to your workplace. Training must be documented (date, content, and worker names) and should be reviewed after any incident involving plant isolation, after new equipment is installed, or when procedures change. New workers must be trained before performing any LOTO activity.
