In the humming heart of Australia’s worksites—where machinery whirrs, pressure builds and electrical circuits course with power—safety isn’t just a policy. It’s a promise. One critical piece of that promise is the use of Lock Out Tags, also known as Lockout Tagout (LOTO) systems.
From bustling construction zones to quiet maintenance rooms, Lock Out Tags are the unsung heroes protecting lives from the invisible danger of uncontrolled energy. If you work with, near or even around powered equipment, this isn’t just a box-ticking WHS requirement—it could be the difference between life and death.
So let’s dive into what Lock Out Tags are, how they work, why they matter and what best practices look like in the Australian context.
What Are Lock Out Tags?
A Lock Out Tag is a visual warning and procedural safeguard used during maintenance or servicing of machinery. These tags are typically attached alongside a physical lock on energy isolation points—like switches, valves or circuit breakers—to warn that the equipment must not be operated.
The system prevents machines from being inadvertently switched on or activated while someone is still working on them. The Lockout Tag acts like a high-vis vest for the equipment, declaring loud and clear: do not touch, someone’s life is on the line.
But here’s the crucial bit—Lock Out Tags don’t work in isolation. They’re part of a broader Lockout Tagout system that includes procedures, training, standardised devices, and compliance with national regulations.
Why Lock Out Tags Are So Important
Every year, Australian workers are injured—and sometimes killed—when equipment starts unexpectedly during servicing. The culprits? Stored or residual energy: electrical surges, hydraulic pressure, mechanical movement, even gravity.
That’s where Lock Out Tags come in. They’re your frontline defence against these deadly scenarios. By using a Lockout Tag system, you isolate the energy, tag the point, and lock it down so no one can accidentally flick a switch, release a valve or activate a machine mid-task.
Regulations require that machines be fitted with lockable controls and that maintenance be conducted in a safely isolated state. Most states and territories in Australia follow a harmonised WHS model, reinforcing the importance of having a compliant Lockout Tagout system in place.
Lock Out Tags are just one crucial component of a broader workplace safety system designed to prevent accidents and save lives. At New Signs, we specialise in comprehensive Workplace Safety Signage, offering everything from Danger Signs, Warning and Caution Signs, and Emergency Information Signs to Fire Safety Signs, Mandatory Signs, and Prohibition Signs—ensuring your site is compliant, clear and above all, safe.
How Lock Out Tags Work: A Step-by-Step Process
An effective Lockout Tag system is never haphazard. It follows a strict, methodical process designed to keep everyone safe:
Shutdown and De-energize
The first step involves powering down equipment and isolating it from all energy sources—electricity, gas, hydraulic pressure etc.
Apply Locks and Tags
Each worker involved in the job attaches their own lock and Lock Out Tag to the relevant isolation point. This ensures accountability—only that person can remove their lock and tag.
The Lock Out Tag typically displays key information: the worker’s name, contact number, the date and the reason for the lockout.
Verification
Before work begins, workers must verify that the equipment is truly de-energised. This step is critical—some energy sources, like capacitors or pressure systems, can retain power.
Completion and Removal
Only once the job is finished and all tools are clear, may the original worker remove their lock and Lockout Tag. No one else is authorised to do so.
Types of Lock Out Tags Used in Australia
Australia’s WHS environment recognises that different scenarios call for different tags. Here’s a breakdown of the most common types:
Personal Danger Tags
These are the most crucial tags and must always be used alongside personal locks. They indicate that a specific individual is working on the equipment and that it must not be activated under any circumstance.
Information Tags
These provide context for the isolation—such as maintenance notes, hazard warnings, or additional safety instructions. While not a substitute for a Lockout Tag, they’re useful for communication and record-keeping.
Barricade Tags
Used in conjunction with caution tape or danger tape, these tags help restrict access to hazardous areas. They’re often found on construction sites, around open pits or in areas where machinery is actively being serviced.
Australian Standards and Regulations You Need to Know
Lockout systems in Australia are governed by several key standards and regulations, each carrying real legal weight:
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AS/NZS 4836:2011 – Safe working on or near low-voltage electrical installations. This outlines how to isolate and work around electrical systems safely.
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AS 4024.1603-2006 – Covers machinery safety, particularly the prevention of unexpected start-up.
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WHS Regulation 2011 – This regulation mandates isolation and lockout capabilities in equipment design and outlines the legal responsibilities for employers and workers.
Ignoring these isn't just risky—it’s unlawful. Penalties for breaches can include fines, shutdowns, or worse—serious injuries or fatalities. It is essential that you are familiar with each of the standards to ensure compliance.
Key Elements of a Strong Lockout Tagout Program
To build a compliant, robust system, every Australian business should ensure their Lock Out Tag procedures include the following pillars:
Written Procedures
Have documented policies that are machine-specific and accessible to all relevant personnel.
Clear Identification of Isolation Points
Every energy source must be clearly marked and its isolation procedure fully understood.
Comprehensive Training
Training isn’t a one-time box-tick. It must be regular, relevant and updated in line with equipment or procedural changes.
Proper Devices
Ensure all sites are stocked with standardised locks, Lockout Tags, and isolation tools.
Periodic Reviews
Conduct annual audits and update your Lockout Tagout program to align with current WHS regulations and operational realities.
Best Practices for Australian Workplaces
Even with all the right tools, Lockout Tags are only as good as the culture that supports them. Here are best-practice behaviours that every worker and site manager should adopt:
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Always use both a lock and a tag. The tag provides critical information, but it’s the lock that ensures physical security.
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Never remove someone else’s tag or lock. Even if you think the job is done, that’s a hard no.
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Barricade hazardous areas. Use tape and Barricade Tags and tape to clearly signal danger zones.
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Review procedures regularly. Laws evolve. So should your lockout system.
Your Tag, Your Responsibility
A Lock Out Tag might seem like a small piece of plastic and paper—but in reality, it’s a loud, visible declaration: "I’m working here. My safety depends on you following the rules."
Across Australia’s high-risk industries, from mining and manufacturing to utilities and construction, Lockout Tags aren’t just safety gear—they’re personal insurance policies and legal obligations rolled into one.
Whether you’re a safety officer auditing your procedures or a new apprentice learning the ropes, understanding how to use Lock Out Tags correctly isn’t optional. It’s essential.
So ask yourself: is your Lockout Tagout system up to Australian standards? If not, it’s time to lock in your safety—literally.
FAQ's
1. What is a Lock Out Tag?
A Lock Out Tag is a safety tag used to warn others that machinery is isolated and must not be operated. It’s used with a lock to prevent accidental start-up.
2. Are Lock Out Tags legally required in Australia?
Yes. Lockout Tagout procedures, including Lock Out Tags, are mandatory for certain workplaces in Australia.
3. Can I remove someone else’s Lock Out Tag?
No. Only the person who applied the Lock Out Tag and lock can remove them. This is a strict rule to ensure safety during maintenance or repair.
4. What types of energy sources require lockout?
All hazardous energy sources—including electrical, hydraulic, pneumatic, mechanical, thermal and gravitational—require proper isolation and tagging.
5. Do Lock Out Tags expire or need replacing?
Yes. Tags should be regularly inspected for wear, fading or damage and replaced as needed to ensure visibility and compliance with safety standards.