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LOCKOUT-TAGOUT

What is
lockout-tagout?

Lockout-Tagout or LOTO is a procedure in which security locks, locks (lockouts) and safety tags (tag outs) are used to carry out safe and energy-free work on machines or processes.

This means all energy sources are isolated, locked and provided with a safety tag before the start of the work.

Abus, Brady
en Master Lock
Complies with
OSHA 1910.147
Key
registration

Lockout-tagout solutions

All lockout-tagout (LOTO) materials for safe maintenance of machines.

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Contact our specialists

Writing a lockout-tagout procedure

Drawing up and implementing a successful lockout tagout procedure can be a complex matter. To draw up a procedure as efficiently and safely as possible, an assessment of the current safety procedures (work permits), skills of the operators and an analysis of the installations, is required.

If a lockout tagout procedure is drawn up or maintained incorrectly, this could lead to production loss, hazardous situations and even injury.

A proper lockout tagout procedure complies with legislation and directives, but has also been implemented in all layers of the organisation and with all employees and is, as such, not merely a policy document.

Unique Safety Product can offer the following lockout tagout programs that can take care of the whole or part of the problem:

lockout tagout procedure

Lockout-tagout training

Being a good employer requires you to enable your staff to work safely on machines and installations.

Lockout-tagout training days are a very efficient tool in order to correctly follow the LOTO procedure and detect any hazards.

In cooperation with Pilz Nederland, Unique Safety Products has developed a training program in which all aspects of the implementation of lockout-tagout are discussed.

Padlocks for
lockout-tagout

Safety padlocks are designed for Lock-Out, Tag-Out, Try-Out also known as LOTOTO applications and are used for locking energy sources.

By making use of colour codings (and optionally laser engravings), the function and the owner of the padlock can be identified.

Personal safety padlocks work in accordance with the principle: 1 employee = 1 padlock = 1 key (OSHA Standard 1910.147). If 1 employee needs multiple padlocks or group-lockout has been used, in general, keyed alike padlock sets are applied.

Safety padlocks have at least the following properties:

  • Different colour codings (optionally with laser engraving)
  • Fixed key when the shackle is open
  • 1 padlock = 1 key
  • Different key systems (master key, keyed alike, keyed different)
  • Coded locks with (optionally) key registration
  • Non conductive body/bracket
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master lock 410 lockout-tagout padlock
lifeguard key registration
LifeGuard key registration

Safety padlocks are equipped with a safety cylinder that allows at least 40,000 unique key codes to be assigned.

Abus, Brady and Master Lock all offer the possibility of key registration on the end user to completely rule out the issue of duplicates.

key plan safety padlocks
Key plan

Part of drawing up a LOTO procedure is registering the key plan. This specifies the following:

  • The number of personal padlocks required.
  • Number of employees with a set of equally coded padlocks
  • Use/don't use a master key system
  • Number of generic coded sets for group lockouts
padlocks colour codings
Coloured padlocks

Safety Padlocks are colour coded to indicate the lock function. There is no official standardization for this, but there is industry-leading practice:

  • Red: machine padlocks
  • Blue: technical service
  • Green: release of locks (machine supervisor)
  • Yellow: external employees
1 employee 1 padlock 1 key
1 key = 1 lock

Lockout tagout procedures are often based on the regulations as recorded in OSHA 1910: 147.

This describes that lockout-tagout safety padlocks must be used and supplied according to the following principle:
1 employee = 1 padlock = 1 key, to minimize misuse as much as possible.

padlocks laser engravings
Engraving padlocks

Safety padlocks locks are often provided with a permanent laser engraving to identify the lock and the key.

Engravings can be placed on the front, back, left side, right side and on the key. It is also possible to engrave a company logo.

master lock 428 lockout hasp

Lockout hasps to put
more padlocks on
an isolation point

Lockout hasps are used when an isolation point needs to be locked with multiple personal safety padlocks.

Only when all padlocks have been removed from the lockout hasp it can be released so that the power source can be reactivated.

  • Available in various materials such as nylon, stainless steel or aluminum
  • Safety tags available with a lockout hasp function
  • Different shackle diameters, for mounting on small electric padlock holes

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lockout hasp with tag
Lock-out hasp with tag

Lockout hasps with a safety tag are available from both Brady and Master Lock and are available in 5 different colours and can both accommodate up to 6 padlocks.

421 lockout hasp master lock
Sizes and materials

Lock multipliers are available in many sizes and materials, such as nylon for electric applications or entirely INOX for the food industry.

Tags identify activitities
and isolation points

A safety tag with a safety padlock is placed near isolated locked energy points
to warn that work is in progress.

The tag states who carries out the work and when the work will take place. Safety tags have a warning pictogram with accompanying text. Identification tags are permanently placed on isolation points for identification. The numbers on these tags can be found on the procedure sheet.

  • Available as one-off tags and rewriteable tags (Guardian Extreme)
  • Metal detectable version available for the food industry
  • Design the tags yourself, optionally with sequential numbering.
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abus T150 safety tag
rewritable safety tag
Rewritable and erasable

Brady and Masterlock deliver a broad scala of rewritable and erasable safety tags for nearly every type of application.

These safety tags are writable with a permanent marker and can be wiped clean with alcohol wipes. These safety tags are also suitable for outdoor use.

For the food processing industry, we also supply “metal detectable” tags that can be detected if they end up in the production process.

customized safety tags
Personalised tags

Customized safety tags according to your wishes and specifications. Unique Safety Products designs and manufactures both reusable and one-off personalized safety tags for every industrial environment.

​Provide the tags with your logo and optionally with sequential numbering.

tags for isolation points
Tags for isolation points

Isolation tags are used to mark the control points of the energy sources. The machine-specific lockout procedure refers to these isolation points and indicates in which order and with which locks the relevant energy source should be locked.

Isolation point tags exist for all types of energy sources and are numbered per energy type from 1 to 20.

lockout-tagout valves

Lockouts for electrical
and mechanical
dangers

Lockout-Tagout-Tryout locks are designed especially for the locking of energy sources during maintenance or cleaning activities.

These lock-outs are positioned on the isolation point of the energy source and subsequently locked with a safety padlock and marked with a safety tag.

The Lock-Out devices are available for the following energy sources:

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lockouts for valves
Lockouts for valves

After the handwheel has been set to the lockable position (open or closed), it can be easily locked with a valve lockout, available in different sizes and colours.

It is also possible to use cable lock-outs to lock handwheel valves.

electrical locking devices
Electrical locking devices

Electrical locking devices are available for almost all types of circuit breakers. These lockouts are designed to, in combination with a safety padlock, secure the machine against being switched on again.

There are also, lock-outs are available for screw-type fuses, knife blade fuses (NH-fuses), plugs, push buttons and emergency stops.

ball valve lockout
Lockouts for ball valves

Ball valves come in a wide variety of shapes and sizes

Therefore, use universal ball valve lockouts or a cable lockout that is secured with a grip-tight to a fixed pipe nearby.

pneumatic pipes lockout
Pneumatic lockout devices

Airlines can easily be secured against connections with pneumatic coupling locks.

Universal lockouts fit on many different pipe couplings.

lockout tagout confined spaces
Confined spaces

To prevent containment in confined spaces and manholes, covers are used that optionally can be locked with a safety padlock.

cable lockouts
Universal cable lockouts

Cable locks are the ideal multi-functional solution for locking energy sources.

Use cable lock-outs for locking valves, ball valves and various circuit breakers

lockouts for butterfly valves
Lockouts for butterfly valves

With a universal insert, a butterfly valve can easily be locked in combination with a cable lockout and safety padlock.

The butterfly valve lock-out prevents the handle from being squeezed and the valve from being opened.

Blind flanges lockouts

When blind flanges are positioned during maintenance activities, the undesired removal of the blind flange can be prevented by placing blind flange lockouts, which can be locked with a safety padlock.

Blind flange locks are available in 3 different sizes.

Lockout stations
organize LOTO
materials

Lockout stations or padlock stations are used for the organised and clear storing of lockout-tagout materials.

By placing the lockout station near the relevant installation and providing it with the necessary materials to secure this installation, the LOTO procedure becomes clearer and safer.

  • Available in different sizes
  • Made from steel or impact-resistant plastic
  • Permit to work station combines a group lock box with a padlock station for more functionality
  • Lockout stations can be provided with storage bins for the storing of lockout materials
  • Possibility to produce shadow boards in different sizes
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lockout-tagout station
master lock lockout station
Lockable lockout stations

For a well-organized storage space for your padlocks, tags and lock multipliers, Master Lock has launched 3 different lockable lockout stations.

  • 1482B | 5 safety padlocks
  • 1483B | 10 safety padlocks
  • 1484B | 20 safety padlocks
padlock station compact master lock
Filled lockout stations

In addition to self-divisible empty stations, there are also pre-assembled lockout stations and lockout kits containing the most necessary materials for electrical and/or mechanical lockout.

abus lockpoint
Lockpoint

ABUS Lockpoints are developed to easily create an organised storage station yourself, for all your lockout-tagout materials.

You can easily attach padlock rails, storage bins, group lock boxes and procedure sheet holders. You can personalise the lock point with your own logo.

master lock group lockout

Group lock boxes
lock boxes for
group lockouts

Group lock boxes are used during a group lockout. The principle of this is that an authorized employee isolates and locks all energy sources with a set of keyed-alike safety padlocks. 

The key of this set then goes into the group lock box. After which every employee or contractor working on the installation places his or her safety padlock on the lock box.

Only when all safety padlocks are removed from the lockbox can the key be removed to unlock and reactivate the energy sources.

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s3500 work permit station
Work permit station

A work permit station is a group lock box equipped with a procedure sheet holder and a padlock carrier.

This makes that the station can be used as a starting point for more complex lockout tagout procedures.

abus b835 lock box
Portable lockboxes

Portable group locks can be taken to the installation where lockout tagout is performed.

When all energy sources are isolated by the person responsible for the group-lockout and he has placed his personal padlock, everyone performing work activities can place his padlock (and tag) on this box near the installation.

complex group lockout
Complex lockout

A complex lockout requires a large number of different energy sources to be isolated, a work permit is required and there are many employees involved.

The use of group locks in complex lockout reduces the number of safety padlocks required and helps to perform large maintenance jobs more safely and efficiently.

Schadow boards
optimalise your
LOTO procedure

Shadow boards help improve lockout tagout procedures and provide a visualization of the required materials and the work permit.

Shadow boards help operators find the necessary lockout materials for their operations. The coloured shade of the materials provides immediate insight into which materials are in use.

Shadow boards make LOTO procedures a lot more clear and efficient and they reduce the risk of accidents during cleaning and maintenance of industrial equipment and processes.

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custom lockout shadow boards
lockout 5s workplaces
5S workstations

Poorly organized workplaces and work environments reduce employee productivity.

Shadow boards provide more overview, clarification of the available and required lockout materials and help you achieve your lean 5s objective.

custom shadow board lockout tagout
Custom shadow board

Shadow boards are custom made and contain the materials you use during lockout tagout work. Shadow boards are printed on plastic and have a solid aluminium edge.

Indicate which materials you want to place on the board and we will take care of the design and implementation.

lockout procedures with permit
Connect to LOTO procedures

Have your lockout tagout procedures refer to the materials on the shadow board, so everyone can immediately see what work is being performed.

By placing a work permit display, the relevant permit is immediately visible to everyone.

Lockout kits
pre-assembled sets
for technicians

Lockout kits are pre-assembled sets with LOTO materials for installers, mechanics or technicians. The kits are equipped with a portable waist bag or tool case. We divide LOTO kits into kits for electrical and mechanical work.

For common lockout tagout activities, it is efficient to carry a lockout kit, so that simple LOTO's can be carried out quickly and safely.

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abus lockout-tagout kits
lockout kit electric
Electrical lockout kits

Vergrendelingssets voor elektrische gevaren zijn zo samengesteld dat de meest voorkomende elektrische installaties kunnen worden vergrendeld en gemarkeerd. Elektrische kits bevatten doorgaans geïsoleerde veiligheidssloten, veiligheidstags, automaatvergrendelingen en stekkervergrendelingen.

lockout kit mechanical
Mechanical lockout kits

Lockout sets to prevent mechanical dangers for technicians and the technical service department include as many universal locks for valves and ball valves as possible.

Usually, the set is also provided with a cable lock to lock non-standard valves to a fixed point or pipe.

lockout kits compile your own
Assemble your own kit

You can select the necessary materials for a set yourself or let our sales engineers advise you on how to put together the lockout kit that best suits the maintenance activities.

Lockout kits can also be marked per technician with name, position or company information.

Pipe markers
to identify substances
in pipes

Pipe markers are used to identify (hazardous) substances that run through pipes.

The use of pipe markings is documented in European Directive 92/95. The correct use of colours and symbols is also registered in this guideline.

For European uniformity, the NEN3050 specifies the use of different substance names and colours for pipe markers. To meet this requirement, our pipe markers are divided into the following categories:

  • Acids
  • Alkalis
  • Air
  • Flammable liquids
  • Non vlammable liquids
  • Fire fighting
  • Gas
  • Steam
  • Water
  • Oxygen
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pipemarkers
pipe marking for dangerous substances
Placing pipe markers

According to both National and European regulations, pipes must be marked at every connection point:

  • Inputs of the valves
  • Outputs of the valves
  • Devices
  • Access points
  • Panels
  • Walls
apply brady pipe markings
CLP hazard pictograms

The CLP regulations (classification, labelling and packing) issued by the GHS (Globally Harmonized System) are mandatory as of December 1, 2010 and indicate whether and which hazard pictograms should be displayed per substance.

brady pipe markings clp symbols
Different types of pipe markers

All standardized pipe markers are made from laminated polyester. Pipe markings are resistant to UV light, high and low temperatures and are provided with all legal inscriptions, colours and symbols.

Pipe markings are available in seven different standard sizes, on a roll and with or without a carrier.

Label printers print
tags, labels and
pipe markings

Brady has a wide range label printers for industrial applications such as identification, tags, labels, pipe markers and safety signs.

Brady's industrial print solutions offer a multitude of options for labelling and marking within your organization. By using durable patented label materials and the supplied software, you can easily create custom labels that meet the guidelines.

Use Brady printing solutions for:

  • Safety pictograms
  • Pipeline coding
  • Barcode labels
  • General Signaling
  • Safety tags
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label printer brady s3000
brady s3100 label printer
Printing pipe markers

Print your own pipe markings that comply with the CLP regulations. They are provided with the correct symbols, layout and colour scheme. Brady label materials are designed to withstand large temperature differences and humidity for years.

label printers for danger pictograms
Multifunctional printers

We help you select the right printing solution for your application, from handy portable printers for labelling to advanced multifunctional solutions for printing tags and pipe markers.

brady consumables and labels
Patented print labels

Brady offers a suitable print label for every application. There is a choice in different materials, dimensions, coatings, carriers and colours. Brady has more than 30 patented innovations, making it the market leader in industrial label solutions.

We are
here to help

Contact one of our technical specialists or sales engineers

Sales engineer Marco Heijkoop small

Marco Heijkoop

Sales Engineer

marco.heijkoop@usp-safety.com
Sales engineer Rick de Jonge small

Rick de Jonge

Sales Engineer

rick.dejonge@usp-safety.com
Internal sales coördinator Michael Dissel small

Michael Dissel

Sales coördinator

michael.dissel@usp-safety.com
Technical specialist Bob Wijnveldt small

Bob Wijnveldt

Technical Specialist

bob.wijnveldt@usp-safety.com
Rob Voordendag small

Rob Voordendag

rob.voordendag@usp-safety.com
Robert van de Ven small

Robert van de Ven

robert.vandeven@usp-safety.com

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