Safety Lockout Tags

Safety lockout tags

Lockout-tagout tags are the physical and legal signals that isolated equipment must not be re-energised — attached to padlocks, switches, and valves during maintenance, repair, and construction work. Under Australian WHS regulation, lockout-tagout is mandatory for any plant or machinery maintenance where unexpected energisation could cause injury.

Types of lockout tags

• "Danger — do not operate" tags — red/black "DO NOT OPERATE" tag used when the isolation is done by the maintainer for their own protection.
• "Out of service" tags — yellow/black "OUT OF SERVICE" tag used when equipment is withdrawn from service pending repair.
• "Personal danger" tags — individual tags with worker name, date, and reason — signed by the specific worker whose safety depends on the isolation.
• "Permit" or "procedure" tags — site-specific tags for controlled-work-permit systems (hot work, confined space, working at heights).

Lockout-tagout procedure

A compliant LOTO procedure under AS 4024.1603 includes:

1. Notify affected workers.
2. Shut down and isolate all energy sources (electrical, mechanical, hydraulic, pneumatic, thermal, gravitational, stored).
3. Apply a lockout device (padlock, valve lock, plug cover) to each isolation point.
4. Attach a personal danger tag signed and dated by the worker performing the isolation.
5. Verify zero-energy state by attempting to operate the equipment.
6. Perform the work.
7. Reverse the procedure to restore service.

Tag construction

Compliant lockout tags are tear-resistant, weatherproof, and carry the worker's name, date, and reason for isolation. Writable surfaces let each tag be personalised to the specific isolation. One-use tear-away tags prevent tag reuse that could undermine the integrity of the procedure.

Pair with lockout devices

A tag without a lock is an advisory — a lock without a tag doesn't identify who performed the isolation. Both are required for compliant LOTO. See our lockout padlock and valve lockout ranges for the physical isolation devices that pair with these tags.

Standards & compliance

Lockout-tagout is regulated under AS 4024.1603 and the state-based WHS regulations. Sites with plant or electrical maintenance work must have a documented LOTO procedure aligned with the standard.

Frequently asked questions

Who's allowed to remove a personal danger tag?

Only the worker whose name is on the tag, except under a formal emergency tag-removal procedure supervised by site management — and only after verifying the worker is no longer exposed. Removing someone else's tag without authorisation is a serious safety breach.

Are reusable tags acceptable?

Many sites allow reusable tags with writable/wipeable surfaces for ongoing maintenance programs. For one-off or occasional isolation, tear-away tags provide clearer accountability.

Does a site need different tags for different isolation types?

Yes — distinct tags for personal danger (workers' own safety), out of service (equipment condition), and permit work (controlled-work-permit systems) support clearer communication. Consolidating all isolation to a single tag type creates confusion.

Do you offer trade or bulk pricing?

Yes — trade accounts get 5% off RRP, and LOTO programs are typically ordered in carton lots with site-specific pricing. Apply for a trade account →