In trade environments, machinery and equipment are part of everyday work. But when equipment needs to be cleaned, inspected, repaired or maintained, simply switching it off may not be enough to make it safe.
Machinery can be accidentally restarted, and energy can remain stored within equipment even after it has been shut down. That is where lockout and tagout procedures, commonly referred to as LOTO, become an important part of workplace safety.
Lockout and tagout procedures are designed to prevent machinery or equipment from being unexpectedly energised, started or releasing stored energy while someone is working on it. SafeWork NSW describes isolation procedures as predetermined steps used when workers undertake tasks such as maintenance, repair, installation and cleaning of plant.
What Is Lockout and Tagout?
Although the terms are often used together, lockout and tagout perform different functions.
Lockout involves physically securing an energy isolation point so that machinery or equipment cannot be re-energised while work is being carried out.
Tagout involves attaching a clearly identifiable tag to communicate that equipment has been isolated and must not be operated.
The lock provides the physical control, while the tag provides important information and warning to other people in the workplace.
This distinction matters. A warning tag on its own does not physically prevent someone from operating equipment. An effective isolation system needs to account for the equipment, its energy sources, the work being performed and the workplace’s established procedures.
Why Simply Switching a Machine Off Isn’t Always Enough
One of the biggest reasons isolation procedures are important is that machinery can contain several different forms of energy.
Electricity may be the most obvious, but depending on the equipment, workers may also need to consider pneumatic pressure, hydraulics, compressed springs, gravity, heat, steam, fuels and other stored or transmitted energy. Australia’s model Code of Practice for managing plant risks specifically identifies these types of energy when considering plant isolation.
For example, shutting down the electrical controls of a machine does not necessarily mean hydraulic pressure has been released or that an elevated component cannot move.
Effective isolation is therefore about more than pressing the stop button.
When Is Lockout and Tagout Used?
LOTO procedures may be required whenever a worker could be exposed to dangerous energy from plant or equipment.
Common situations include:
- Cleaning, inspecting, servicing or repairing machinery
- Performing maintenance
- Clearing faults or working on damaged equipment
- Installing, commissioning or decommissioning plant
- Removing guards or accessing hazardous areas of machinery
- Working on equipment where stored energy could unexpectedly be released
The exact isolation procedure will depend on the equipment and workplace. Workers should always follow their organisation’s procedures and only carry out tasks for which they have been appropriately trained, instructed and authorised.
What Does an Effective Isolation Process Involve?
The specific process can vary, particularly with complex equipment or multiple energy sources, but the basic principle is to make sure the equipment cannot unexpectedly operate while someone is in a position where they could be injured.
SafeWork guidance commonly includes identifying the machinery and hazards, identifying and isolating energy sources, dealing with stored energy, locking isolation points, applying appropriate tags and verifying that the isolation is effective before work begins.
Where multiple workers are involved, isolation arrangements also need to protect each individual worker. Australia’s model Code of Practice notes that, where practicable, each worker involved in maintenance, cleaning or repair should have their own lock, tag and key associated with the isolation arrangement.
The important point is that LOTO is a system, not simply a padlock and a tag.
Communication Is Just as Important
Trade safety relies heavily on communication.
A properly implemented tag helps other workers understand that equipment has been isolated, why it is unavailable and who is involved in the work.
This becomes particularly important on larger sites where several tradespeople, supervisors, contractors or shifts may interact with the same equipment.
WorkSafe Queensland also emphasises that isolation processes should form part of a broader safety management system, including risk assessment, consultation, training and ensuring workers carrying out the task are competent to do so.
Lockout and Tagout Is Everyone’s Responsibility
Safe isolation isn’t only relevant to the person physically carrying out the repair.
Employers need appropriate systems, procedures, equipment, instruction and supervision in place. Supervisors need to reinforce those procedures. Workers need to understand and follow the workplace’s isolation requirements and avoid interfering with another person’s lock or tag.
For apprentices in particular, learning these habits early is an important part of developing into a safe and competent tradesperson.
If you’re unsure about an isolation process, the answer shouldn’t be to guess. Stop and speak with the appropriate supervisor or competent person before proceeding.
Building Safe Habits From the Beginning
Technical skills are obviously a major part of learning a trade, but being trade-qualified is about more than knowing how to fabricate, repair, install or maintain something.
It also means understanding how to carry out that work safely.
Recognising hazards, following isolation procedures, communicating with the people around you and knowing when equipment is safe to work on are skills that can protect both the worker carrying out the task and everyone else in the workplace.
At Gimbal Training, we believe developing safe work practices is an important part of building capable, job-ready tradespeople.
Whether you’re an apprentice developing your skills or an experienced tradesperson, lockout and tagout is one of those workplace safety principles that should never become an afterthought.
Before the work starts, make sure the equipment is properly isolated, the risks are understood and the correct workplace procedures are being followed.