What is lockout/tagout?
Lockout/tagout (LOTO) is a safety procedure that keeps equipment completely shut off while it’s serviced or repaired. In Canada, LOTO is required whenever a worker could be exposed to unexpected startup or stored energy in equipment or machinery, such as when completing maintenance or repair work, regardless of workplace size.
The standard, Control of hazardous energy: Lockout and other methods (CSA Z460-20), defines lockout as attaching a lock to an energy-isolating device, like a breaker or valve, to prevent equipment from being energized.
- Lockout means de-energizing equipment, isolating all energy sources within the equipment, and physically locking equipment so it cannot become re-energized and potentially hazardous. The lock keeps equipment de-energized until the job is done, protecting everyone involved.
- Tagout is always paired with lockout. It adds a clear label showing why the lock is there, when it was applied, and who’s responsible. Only the person who placed the lock and tag can remove them, ensuring equipment can’t restart until it’s truly safe.
Lockout/tagout in Canadian workplaces
It’s 7:40 a.m. on an ordinary Thursday. A maintenance technician begins working on a packaging line at a Calgary manufacturer, replacing a worn part and doing routine maintenance. The entire line was shut down after last night’s shift, and the technician has just completed their lockout/tagout (LOTO) procedure.
To replace the part, the safety guards were removed, and now the technician’s hands are working inside the facility’s conveyor belt system as the morning shift starts clocking in. Whether the technician leaves the job in the same condition they started depends on effective communication, coordination, and proper training.
Was the breaker truly locked and tagged out? Was the key in the tech’s pocket? Or did they just flip the breaker off because they wanted to save time, thinking it was an easy job? That gap between required process and dangerous shortcuts was the focus of this expert-led webinar and this Q&A blogpost.
Lockout/tagout: An employer’s obligation
If a piece of equipment in your workplace can start up or move on its own while someone is working on it, you have a lockout/tagout obligation, whether you run a 50,000 square foot plant, an area of a facility, a commercial kitchen, or an office with a trash compactor.
In this webinar replay, our health and safety consultant, Dustyn, dispels common myths on lockout/tagout, explains what it actually is, the seven forms of hazardous energy your people won’t always see coming, what a compliant procedure has to contain, and the small shortcuts that turn a routine task into a serious incident.
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Lockout/tagout for employers: An expert Q&A
When does lockout/tagout apply?
Adapted from webinar transcript
KP: Dustyn, let’s start right at the beginning. What is lockout/tagout, and why is it such a big deal?
Dustyn: Lockout/tagout is a hazardous energy control procedure. It protects workers while they’re servicing, cleaning, maintaining, or repairing equipment. It stops that equipment from unexpectedly starting up or releasing stored energy while the work is happening.
The part people miss is that hazardous energy isn’t just electrical. It can be mechanical, hydraulic, pneumatic, or even gravitational. If those sources aren’t properly controlled, you’re looking at serious injuries or a fatality. So, the purpose of lockout/tagout is to isolate every hazardous energy source and keep the equipment de-energized until the work is done and it’s safe to bring it back online.
The goal is what we call a zero-energy state: the energy sources are isolated, any stored energy is released or controlled, and you’ve verified the equipment can’t start or move while your people are working on it. Said the simplest way, everything is shut off and there’s no energy left that can hurt you.
Where and who does lockout/tagout apply to?
KP: A lot of people assume lockout/tagout is only for large plants and industrial sites. Is it?
Dustyn: That’s one of the biggest misconceptions out there. It isn’t determined by the size of your business. It’s determined by the work being performed. Manufacturing, warehousing, and construction use it constantly, but it matters just as much in a retail store, a restaurant, or a small office. Every workplace has equipment that can hurt someone.
The question to ask is simple: Can this equipment unexpectedly start or move while someone is working on it? If the answer is yes, you need energy isolation, full stop, regardless of how big the business is, or how small the task looks. A good rule of thumb is what we call “breaking the plane.” The moment a worker reaches a hazardous area with moving parts or live energy sources, lockout/tagout must be in place, and every source must be at zero energy.
The golden rule we come back to all day is this: when in doubt, lock it out. Taking the extra step to protect yourself or a co-worker always beats risking a serious or fatal injury.
The seven types of hazardous energy you can’t always see
KP: Let’s get into different types of hazardous energy, because as you’ve said, it’s not always obvious.
Dustyn: Right, and this is where a lot of serious injuries actually come from. Workers don’t recognize all the forms of energy a piece of equipment can hold.
There are seven worth knowing:
- Electrical: the familiar one. Energized circuits, panels, and powered equipment. Poor isolation means shock, arc flash burns, or electrocution.
- Mechanical: moving parts like conveyors, gears, and rotating shafts. Even after the power’s off, momentum can keep them turning for minutes.
- Hydraulic and pneumatic: pressurized fluids or compressed air and gases. Pressure stays trapped in the system even after you’ve isolated the power, and it can suddenly move parts.
- Thermal: steam systems, heated pipes, anything that stays dangerously hot after shutdown.
- Chemical: hazardous or flammable substances under pressure that have to be safely isolated to prevent exposure or release.
- Gravitational: anything raised or suspended, such as a lift table, elevated components, or a suspended load. If it isn’t secured, it can fall.
- Stored energy: the one to never forget. Even after the equipment is shut down and locked out, energy can stay trapped. It has to be released, restrained, or otherwise controlled before work begins.
The takeaway is that every piece of equipment should be assessed for all potential energy sources before anyone touches it, not just the ones you can see.
Can you use any lock for lockout/tagout?
KP: The name makes it sound like a padlock is the whole story. Is it?
Dustyn: Not at all. You’ll see five devices most often. The personal padlock is the most common, however. It secures an energy-isolating device, like a breaker or disconnect, in the off position, and the key principle is one lock, one key, one worker. Each authorized worker has their own lock, and nobody else has access to that key.
When more than one person is on the same equipment, you use a lockout hasp so everyone can add their own padlock to a single isolation point.
- Valve lockouts secure valves on hydraulic, pneumatic, water, or steam systems.
- Electrical plug-outs stop a removable cord from being plugged back in.
- Group lockout boxes handle bigger jobs: as the equipment is locked out at each point, the keys go in the box, and every worker puts a personal lock on the outside.
Whatever the device, they all do the same job: keep the hazardous energy isolated until everyone is clear.
What must be included in a compliant lockout/tagout procedure?
KP: We’ve covered the what and the where. What actually goes into a good lockout/tagout procedure?
Dustyn: A lockout/tagout procedure is a written, step-by-step document for each piece of equipment and accounts for each energy type. It’s far more than just turning something off. It identifies every hazardous energy source and explains exactly how to isolate each one. Under CSA Z460, that machine-specific procedure is the standard, not a single generic one that’s supposed to cover the whole shop.
What are the most common gaps you see onsite?
KP: You’re visiting jobsites day to day, Dustyn. Where do programs actually break down?
Dustyn: Even organizations with well-established programs develop gaps over time. In most cases, an incident doesn’t happen because the program is missing; it happens because the procedure isn’t followed, isn’t updated, or a worker takes a shortcut. Three come up repeatedly.
- First, outdated procedures: equipment gets modified, upgraded, or relocated, but the lockout procedure doesn’t get updated. If a new energy source or isolation point isn’t captured, workers follow the wrong steps and get exposed.
- Second, contractors and visitors: they don’t know your site’s equipment, so they need to be briefed on your site-specific requirements and any hazardous energy they’ll encounter before they start.
The third one is the biggest, and it’s a mindset: “it’ll only take a minute.” Someone skips the lockout for a quick adjustment or a small jam, and that’s exactly when something happens. That’s the moment everything you’ve put in place gets skipped over.
What should Canadian employers be doing today?
KP: So, what should employers do to keep this handled the right way?
Dustyn: Three things, and they reinforce each other.
- Training comes first. Thorough training means workers understand not just how to perform a lockout, but why every step matters.
- Second, clear and accurate documentation of both your training and your procedures, so everyone follows the same process with the same information.
- Third, regular audits and inspections are important. They confirm procedures are being followed and, just as valuable, they surface ways to improve the program before an incident forces the issue.
Together, those three build a stronger safety program, more consistent work practices, and a real reduction in the risk of injuries and fatalities.
Quick takeaways for LOTO procedures
- Ask one question of every task: Can this equipment start or move while someone’s working on it? If yes, lock it out.
- Assess all seven energy types: electrical, mechanical, hydraulic, pneumatic, thermal, chemical, gravitational, and stored energy, before anyone breaks the plane.
- Write a machine-specific procedure for each piece of equipment, not one generic policy for the whole site.
- Give each authorized worker their own lock and their own key: one lock, one key, one worker.
- Review procedures at least annually and whenever equipment, processes, or energy sources change.
Lockout/tagout FAQs for Canadian employers
Who is authorized to perform lockout/tagout?
Dustyn: An authorized worker is someone the employer has designated and who has received the training and competency testing to isolate, lock out, and verify hazardous energy, then safely restore the equipment afterwards. They have to be able to follow the equipment-specific procedure, apply their own lock and tag, and verify the zero-energy state before any work begins. Anyone properly trained by the organization for that equipment can be authorized.
How often should lockout/tagout procedures be reviewed?
Dustyn: At a minimum, annually, and any time your equipment, processes, energy sources, or work practices change. An annual inspection confirms every source and isolation point; your devices are in good working order, and your people understand and follow the procedures. Employers should document the review, fix any deficiencies, and retrain where needed. CSA Z460 also expects those audit records to be kept.
Do we need individual locks, or is a shared lockbox fine?
Dustyn: Personal locks are always the better choice. You hold the one key, you keep it on you, and your safety stays in your own hands; nobody else can decide to remove your lock. There should only ever be one key per lock. If a key is lost, you follow a defined procedure to confirm the equipment is safe before removing the lock, rather than keeping spare copies floating around.
Would your lockout/tagout program and procedures hold up to a ministry workplace inspection?
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