Contents
Every facility that services powered equipment needs a lockout/tagout (LOTO) program; it’s a direct requirement from OSHA 1910.147. But a binder of written procedures only works if your team has the right hardware and training to carry them out. If you’re standing up a new program or truing up an outdated one, this checklist walks through every category of equipment you’ll need, what each device does, and how to choose the right version for your facility.
Brand new to LOTO?
Start with the basics: what does LOTO stand for and what a lockout/tagout program includes.
Then, come back here to build your equipment list.
First, match your equipment to your energy sources
Before you buy anything, walk your facility and document every hazardous energy source: electrical, mechanical, hydraulic, pneumatic, thermal, and stored energy. (Here’s a refresher on the types of hazardous energy a LOTO program controls.) Your equipment list should map directly to what you find: a plant full of ball valves needs valve lockouts; an electrical shop needs breaker lockouts and non-conductive padlocks. Once you’ve identified the specific energy sources you need to manage, follow along with the steps below to find the solutions you need.
The lockout/tagout equipment checklist
Safety padlocks: the foundation
Padlocks are the core of every program. Each authorized worker gets their own lock (and only they hold the key), so equipment can’t be re-energized until every person has removed their lock. When you choose padlocks, decide on:
- Keying: Keyed different (every lock unique) for individual accountability, or keyed alike (one key opens a set) for a single worker managing multiple points. Most programs use keyed-different locks and add keyed-alike sets for specific roles.
- Shackle material: Steel for general-purpose durability; non-conductive nylon for electrical work, where a metal shackle could arc.
- Color coding: Assign colors by department, shift, or hazard type so a glance tells you who owns a lock.
A durable, tamper-resistant padlock in a few coordinated colors covers most facilities. Browse safety padlocks and all LOTO devices here.
Lockout hasps for group work
When more than one person works on the same energy source, a hasp lets each of them apply their own padlock to a single isolation point. The equipment stays locked until the last worker removes their lock. Look for hasps that hold up to six padlocks, and choose non-conductive nylon hasps for electrical or corrosive environments and vinyl-coated steel hasps for heavy-duty general use.
Valve lockouts for fluid and gas systems
Pipe and process work calls for valve-specific devices:
- Ball valve lockouts clamp over the lever to lock quarter-turn valves open or closed.
- Gate valve lockouts enclose the handwheel so it spins free without turning the valve.
- Universal valve lockouts with a blocking arm adapt to irregular or hard-to-fit handles.
If your facility runs mixed valve types, a universal option plus a couple of sized ball and gate lockouts will cover most lines.
Circuit-breaker and electrical lockouts
For panels and disconnects, you’ll want clamp-on breaker lockouts sized to your switches (120/277V, 480/600V, and universal fits), plus plug lockouts and cable lockouts for cord-connected equipment. Non-conductive materials are a must here, so pair these with our nylon-shackle padlocks for a fully insulated electrical lockout.
Cable lockouts for odd jobs and awkward angles
A flexible cable lockout threads through and secures multiple or awkward isolation points at once, ideal for side-by-side breakers, ganged valves, or anything a rigid device won’t fit. One adjustable cable lockout is a cheap insurance policy for the situations your standard devices don’t cover.
LOTO Tags for required communication
Every lock needs a tag identifying who applied it, when, and why. Tags are the “tagout” half of LOTO and are required even alongside locks. Stock durable, weather-resistant tags and make sure your team knows where lockout/tagout tags should be placed. Tags and spare padlocks are your ongoing reorder items, so keep them stocked to ensure ongoing compliance and safety. If you have a large facility, or are looking at upgrading your overall HAZCOM program, consider our LabelTac Pro-X LOTO Bundle to save money while improving safety and compliance.
Stations and group lock boxes to keep it organized
A program falls apart when the gear goes missing. Lockout stations mount on the wall and keep padlocks, hasps, and tags visible, stocked, and ready: choose a 10- or 40-padlock capacity based on team size. For complex jobs with many workers, a group lock box holds the energy-isolating keys behind everyone’s personal locks, so the system can’t be re-energized until the last person signs off.
LOTO Kits: the fastest way to start
If you’re building from zero, a lockout/tagout kit is a great place to start: a curated set of padlocks, hasps, breaker or valve lockouts, and tags in a portable bag. An electrical kit outfits a technician for panel work; a valve kit covers pipe and process lines. These kits can help get a new program compliant on day one, then you can expand with individual devices as you find gaps or your needs change.
Put it all together
A complete LOTO program is an ecosystem, not a pile of parts: locks, hasps, device-specific lockouts, tags, and stations should work together so any qualified worker can safely isolate any hazard in your facility. Design and implement your LOTO program based on your specific energy sources, standardize LOTO devices and communication tools, and keep the consumables, tags and spare locks, stocked and replenished based on your facility’s needs.
Once your equipment is in place, formalize the steps your team will follow with these typical lockout/tagout procedures, and make sure the right people understand who’s responsible for the program.
Ready to build or restock your program? Shop the full lockout/tagout line or download our free Lockout/Tagout Guide to plan it out first.