Accidental start-up of machinery during servicing remains one of the biggest risks across industrial worksites. Without proper physical isolation, equipment may reactivate while workers are still performing tasks.
Even when procedures exist, they fail if the correct tools aren’t available. Missing lockout devices, shared padlocks, or unclear tags leave isolation points unprotected — increasing the chance of incident and non-compliance.
A complete lockout tagout (LOTO) system supports safe shutdowns. Below are ten essential LOTO products used across industrial worksites to keep people safe and systems isolated.
1. Lockout Hasps
Lockout hasps allow more than one worker to lock out a single energy source. Each worker applies a personal padlock, and the hasp stays locked until all padlocks are removed.
Hasps are used during group maintenance tasks, plant-wide shutdowns, or any job where shared responsibility is required. They come in steel, aluminium, or non-conductive materials to suit the environment.
2. Safety Padlocks
Each worker should use their own padlock during lockout. These padlocks are uniquely keyed and usually labelled with the worker’s name or ID. Colour-coded locks help teams identify departments or task types quickly.
Padlocks are available in plastic, aluminium, and stainless finishes and must be tamper-resistant. Only the person who applied the lock should remove it — a fundamental LOTO rule.
3. Valve Lockouts
Valve lockouts stop valves from being operated during maintenance. These are designed to match the valve type:
- Ball valve lockouts hold the lever in place
- Gate valve lockouts block the wheel from turning
- Butterfly valve lockouts restrict access to the handle
They prevent pressure from being released or flow systems from recharging during servicing.
4. Circuit Breaker Lockouts
Circuit breaker lockouts attach to switchboards and prevent the breaker from being switched on. They are selected based on the size and design of the circuit breaker.
These lockouts are used during electrical isolation and help ensure circuits stay de-energised throughout the task. Most include slots for a padlock to keep the attachment secure.
5. Plug Lockouts
Plug lockouts prevent electrical equipment from being plugged in while being serviced. They enclose the power plug and secure it shut with a padlock.
These devices are common for portable tools, pumps, and machines that draw power from a socket rather than a hardwired circuit. Plug lockouts reduce the chance of someone reconnecting the power unintentionally.
6. Cable Lockouts
Cable lockouts are versatile systems that loop through multiple isolation points. The cable is pulled tight and locked using a built-in mechanism or a standard padlock.
This type of lockout works well on grouped valves, handles, or where space prevents the use of rigid devices. Cable lengths vary to suit small or large equipment.
7. Group Lock Boxes
Group lock boxes store the keys to locked-out isolators during work. Once isolation is complete, the keys are placed inside the box. Every worker involved in the task applies a padlock to the box itself.
The system remains locked until every padlock is removed, ensuring no one can restart equipment until the full team has cleared their lock.
8. Lockout Tags
Lockout tags are used to provide clear information about the isolation. Tags show who applied the lock, what task is being done, and when the lockout started.
Tags increase visibility and communication. They’re attached directly to the lockout device and often include warning symbols, safety notes, or job numbers. Durable and water-resistant tags are preferred for harsh environments.
9. Lockout Kits
Lockout kits include a selection of LOTO devices used in daily isolation tasks. These kits are portable and commonly issued to maintenance teams or contractors who move between sites.
A typical kit includes:
- Safety padlocks
- Lockout tags
- Hasps
- Cable or circuit breaker lockouts
Kits ensure workers always have access to the tools needed to carry out safe isolation.
10. Lockout Stations
Lockout stations store isolation equipment in a dedicated location. They help organise LOTO tools, reduce downtime, and support consistent use across departments.
Stations may include:
- Hooks for tags
- Racks for padlocks
- Compartments for valve or cable lockouts
Wall-mounted options are used in fixed work areas, while portable versions are used in larger facilities or outdoor jobs.
Why LOTO Products Are Essential
LOTO gear physically stops energy from reaching the machine or system during service. Each product plays a role:
- Hasps support team lockouts
- Padlocks maintain individual control
- Tags show who is working and when
- Devices keep systems secured from unplanned restart
Correct use of LOTO equipment helps meet WHS requirements, reduces injury risk, and ensures all workers are protected before, during, and after a task.
Secure Your Facility with Locksafe
At Locksafe, we supply Lockout Tagout products built to help teams isolate energy safely and efficiently. From hasps and safety padlocks to complete lockout kits, our gear supports safe servicing and helps meet safety standards across all types of worksites.If your site needs lockout tools that match your equipment and energy types, contact us to request product details or set up a supply order.
