Lockout Tagout Guide for Australian Workplaces

Summary and Quick Takeaways

Lockout Tagout (often shortened to “LOTO”) is a critical safety practice in Australian workplaces designed to prevent machinery or equipment from accidentally starting or releasing hazardous energy during maintenance. This guide breaks down:

The Australian regulations, standards, and codes of practice that govern Lockout Tagout.
What policies and procedures businesses must have in place, including equipment-specific guidance.
Industry-specific applications for mining, construction, and manufacturing.
How to train and assess staff, given there is no nationally accredited Lockout Tagout course.
The essential Lockout Tagout equipment you’ll need, with links to Lockout Tagout equipment from Next Day Safety.
Real-world case studies illustrating the importance of Lockout Tagout.

Whether you’re in mining, construction, manufacturing, or any other industry dealing with hazardous energy, this guide provides practical tips for compliance and best practices. Read on to learn how to create a robust Lockout Tagout program that keeps your people safe and meets Australian regulatory requirements.

This guide is designed for educational purposes and does not replace professional legal advice. Always check the latest WHS regulations in your specific State or Territory, and consult qualified safety professionals where necessary.

Regulations & Standards
When is Lockout Tagout Required?
Policies & Procedures
Industry-Specific Applications
Training & Assessment
Lockout Tagout Equipment
Case Studies & Examples

1. Regulations & Standards

Lockout Tagout in Australia is primarily governed by the Work Health and Safety (WHS) laws, which are harmonised across most states and territories. Under these regulations, businesses (often called PCBUs – Persons Conducting a Business or Undertaking) must ensure that:

All sources of hazardous energy can be isolated so a machine cannot be restarted during maintenance.
Workers are protected from the unexpected release of energy (electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or gravitational).

Specifically, WHS Regulation 2011 (in harmonised jurisdictions) mandates that:

Machinery must be designed or equipped so that operator controls can be locked in the “off” position.
Before maintenance, employers must ensure the equipment is shut down, isolated, and cannot move or energise.

For instance, the Model Code of Practice: Managing the Risks of Plant in the Workplace from Safe Work Australia recommends formal lockout/tagout procedures. It states that a reliable system to isolate energy is essential to manage plant risks.

In addition to WHS laws, there are Australian Standards providing detailed technical guidance, such as:

AS/NZS 4836:2011 – Safe working on or near low-voltage electrical installations. Emphasises isolating electrical circuits at the switchboard and using locks/tags.
AS 4024.1603-2006 – Focuses on preventing unexpected start-up of machinery, ensuring they have lockable isolators.

Complying with these standards can help demonstrate you’ve taken all reasonably practicable measures to meet WHS obligations.

For industries like mining, separate legislation and specific guidance notes apply. According to a Queensland mining guidance (which can be applied broadly), mines must have formal isolation and lockout procedures. These documents reinforce the principle that before any maintenance or repair, you must:

Shut down and de-energise the plant.
Lock all isolator points with personal padlocks.
Tag the locks with clear identification of who placed them.
Verify the machine is fully de-energised before commencing work.

Failure to follow these steps has repeatedly led to serious incidents or fatalities. Regulators can and do prosecute businesses that neglect to implement Lockout Tagout measures. Large fines and even imprisonment can result if a workplace death or severe injury is caused by inadequate isolation.

Overall, from the legal standpoint, it’s crystal clear: whenever tasks expose workers to potential start-up or energy release, you must implement Lockout Tagout. This extends to all industries where dangerous energy sources are present—manufacturing plants, construction sites, mines, and more.

2. When is Lockout Tagout Required?

Lockout Tagout is required whenever there is a possibility of injury due to the accidental start-up of machinery or release of hazardous energy. This generally includes:

Maintenance, repair, or servicing of equipment.
Cleaning or unjamming machinery where body parts enter a danger zone.
Inspection, installation, or testing that might expose someone to moving parts or live energy.
Adjustments requiring guards to be removed or bypassed.

Essentially, if a worker could be harmed by unexpected motion, electricity, pressure, or other energy form, lockout/tagout must be used. This applies to:

Electrical energy: Locking out the circuit breaker, switch, or fuse.
Hydraulic/pneumatic systems: Closing and locking valves, releasing stored pressure.
Gravity: Securing or lowering any elevated loads or machine parts.
Mechanical energy: Blocking or bracing moving components, releasing spring tension.
Thermal/chemical energy: Cooling and isolating hot liquids or chemicals under pressure.

For example, WorkSafe Victoria has repeatedly warned that equipment must be isolated and locked out before workers do repairs or clearing tasks on conveyors, presses, mixers, or any high-risk machinery. Unfortunately, many fatalities have occurred when someone assumed hitting an “off” button was enough, only to have the machine restart unexpectedly.

The bottom line: if there’s a risk of unexpected motion or energisation, you must lock it out and tag it out to comply with Australian WHS regulations and ensure workers’ safety.

3. Policies & Procedures

Having a strong Lockout Tagout policy and documented procedures is essential for compliance. A policy generally outlines:

The purpose of Lockout Tagout (prevent injury from unexpected equipment start-up).
Responsibilities (who is authorised to lock out plant, who must be informed, etc.).
The scope of the program (which tasks and equipment require LOTO).
Training and auditing requirements.

Procedures break down the step-by-step method to:

Shut down the machine using normal controls.
Identify all energy sources (e.g. electricity, hydraulics).
Isolate each source (e.g. turn off disconnect switches, close valves).
Apply locks (one for each worker if multiple people are involved).
Attach tags indicating who locked the equipment and why.
Release or restrain stored energy (bleed pressure, block suspended loads, etc.).
Test or “try out” the controls to verify zero energy.

Equipment-Specific Procedures

Some machinery can be locked out with a single disconnect switch; others may have multiple sources (like electrical, pneumatic, hydraulic, and a backup generator). One-size-fits-all procedures might be too generic for complex machines. Create equipment-specific instructions that list:

All power sources and isolation points.
Detailed steps to lock each point.
How to dissipate stored energy (e.g., bleed valves, discharge capacitors).
Any special hazards (like a secondary control panel hidden away).

Post these instructions near the machine or include them in your maintenance manuals so workers can easily reference them.

Good vs. Bad Documentation

Good documentation:

Is clear, detailed, and user-friendly.
Specifically names each isolator (e.g. “Electrical panel #3, breaker #2”).
Lists how to handle stored energy (e.g. “release hydraulic pressure via bleed valve before applying padlock”).
Identifies responsibilities and exactly who can remove locks.
Is readily accessible near the machine or in a known location.

Bad documentation:

Is vague or incomplete (e.g. “Turn off machine and lock it” without specifics).
Fails to mention multiple energy sources.
Is outdated or not easily accessible to workers.

Poor procedures create confusion or tempt shortcuts, ultimately leading to accidents. Regularly review your documents, especially after an incident, a near-miss, or when machinery is modified.

Storage of Lockout Documents

Your Lockout Tagout procedures should be kept:

At or near the equipment for quick reference.
In a central safety manual or company intranet.
Securely managed and updated (with version control).

Many workplaces have a permit-to-work system or isolation permit that tracks each lockout event. This log ensures everyone knows which machines are locked out, who did it, and why.

4. Industry-Specific Applications

While all industries that handle machinery or hazardous energy must use Lockout Tagout, certain sectors face unique challenges. Below are three of the most high-risk and heavily regulated: Mining, Construction, and Manufacturing.

Mining

Australian mining operations involve large-scale equipment and potentially multiple, complex energy sources (electrical, hydraulic, pressurised air, conveyor systems, etc.). Mines must comply with not only WHS laws but also mining-specific regulations such as those in Queensland or Western Australia.

Mining regulations often require a formal, documented isolation system. According to the Queensland mining guidance, mines commonly use group lockout procedures. For example:

An isolation officer locks out every relevant switch/valve, securing each with a personal padlock.
The keys to those locks go into a Group Lock Box.
Each worker attaches their own lock to that box, so no one can open it (and access the keys) until all workers have removed their personal locks.

This prevents accidental or unauthorised re-energising of large, complex systems. High-voltage equipment, lengthy conveyor belts with multiple isolation points, and large hydraulic devices require rigorous lockout measures to prevent serious or fatal incidents.

Additionally, mines often combine permit-to-work systems with Lockout Tagout. A permit detailing isolation steps is issued for each job, and no maintenance starts until the permit is authorised. Mining safety culture emphasises never bypassing LOTO for production pressures—complacency can be lethal in such high-energy environments.

Construction

Construction sites are dynamic and constantly changing. Multiple contractors, temporary electrical installations, powered mobile plant, and partial build structures create unique challenges for Lockout Tagout:

Electricians must lock out circuits when working on wiring or switchboards—this is considered High Risk Construction Work under WHS regulations if the circuit could be live.
Heavy machinery (e.g. cranes, concrete pumps, earthmovers) must be powered down and locked if someone is repairing, cleaning, or inspecting them. This might involve removing and locking the ignition key, isolating the battery with a lockable switch, and tagging control levers.
Plumbers and other trades must lock out valves or water/power supplies to ensure no one turns them on mid-task.

Because many trades operate simultaneously, communication is crucial. If you lock out a circuit breaker, everyone else on-site needs to know. Construction companies may use multi-hasp lockouts so each worker can apply their own padlock, or use lock boxes.

Regular site toolbox talks help reinforce Lockout Tagout rules, ensuring no trade restarts equipment that’s under someone else’s lock. Supervisors typically hold the authority to confirm all locks are removed only once everyone is safe and accounted for.

Manufacturing

Factories are perhaps the most commonly cited scenario for Lockout Tagout. Assembly lines, presses, cutting machines, mixers, and conveyor belts—all need isolating for maintenance.

Common issues in manufacturing include:

Frequent interventions (e.g., clearing product jams) that tempt shortcuts.
Multiple operators and shifts needing to maintain the same equipment.
Various energy sources (mechanical, electrical, hydraulic) on a single production line.

Best practice is to have a detailed Lockout Tagout procedure for each major piece of equipment, train all operators on it, and make LOTO a non-negotiable step anytime access to danger zones is required. Some manufacturers also adopt “no lock, no work” policies, meaning if you don’t have your personal lock, you simply cannot perform maintenance.

Because manufacturing equipment can be complex, testing isolation is critical—after locking out, operators or maintenance staff attempt a “start-up” with the normal controls to confirm the machine remains dead. This step is where many accidents can be prevented.

5. Training & Assessment

Under Australian WHS laws, employers must provide information, instruction, and training about hazards and safe work procedures. Because Lockout Tagout addresses serious hazards, thorough training is essential. While no nationally accredited “LOTO licence” exists, businesses must still ensure workers are competent to perform isolations.

Key points on training:

Who needs training? Anyone who could be exposed to hazardous energy or who may need to lock out equipment: maintenance staff, machine operators (if they clear jams or do minor servicing), electricians, plumbers, contractors, etc.
What to cover? The nature of hazardous energies, the company’s Lockout Tagout procedures, correct use of locks/tags, group lockout methods, emergency protocols, and relevant regulations/standards.
Hands-on practice: Practical demonstrations and supervised practice are crucial. Workers should physically apply padlocks, tags, and try “test-starting” machinery to confirm zero energy.
Assessment: Provide a knowledge check (written or verbal) plus a practical demonstration. Workers must show they can identify isolation points and correctly lock/tag them. Keep records of who passed competency checks.
Refresher training: Regulations encourage ongoing refresher sessions, especially if there’s a new piece of equipment, an incident, or a long gap since the last training.

For example, SafeWork NSW and WorkSafe QLD both emphasise that only competent persons should perform isolations. According to a Quee nsland mining guidance, “Workers must be trained and assessed as competent to ensure they understand the operation of the plant to be isolated.” This principle extends to all industries.

Options for Delivering Training

Internal training: Many companies develop their own Lockout Tagout training module, leveraging in-house safety or engineering staff to conduct workshops.
External providers: Some safety consultancies and RTOs offer courses on Lockout Tagout or broader plant risk management. Though not accredited solely as “LOTO courses,” they cover core isolation skills.
On-the-job mentorship: Experienced staff guide newcomers, supervising them on actual lockout scenarios until they demonstrate competence.

Regardless of the method, ensure your program is documented. Training logs, sign-off sheets, or even short assessments ensure traceability if a regulator inquires about worker competence.

Disciplinary Policies & Culture

Many companies designate Lockout Tagout violations as serious misconduct. If someone removes a colleague’s lock without proper authority, that’s grounds for immediate investigation or discipline. Such a stance underscores that LOTO is a life-critical system.

Building a culture of strict compliance means training employees to:

Never operate equipment with a lock/tag attached.
Refuse to begin a task unless every relevant energy source is locked.
Respect the rule: “You install it, you remove it.” (No one else takes off your personal lock.)

A strong Lockout Tagout culture can save lives, prevents injuries, and helps avoid legal consequences.

6. Lockout Tagout Equipment

Effective Lockout Tagout depends on having the right gear. Physical locks and tags provide the “hands-on” security that prevents machinery from being powered. Below are some common categories of equipment:

Safety Padlocks: Personal locks assigned to each worker. They’re usually keyed differently, so only the owner can remove their lock. For reliable, industrial-grade options, check out Lockout Tagout equipment suppliers like Next Day Safety.
Lockout Hasps: Allows multiple padlocks to attach to a single isolation point (e.g., a circuit breaker). Essential for group tasks so each team member can apply their personal lock.
Tags: “Danger – Do Not Operate” tags identify who locked the equipment and why. Though tags alone are insufficient for lockable points, they’re critical for communication.
Valve Lockouts & Circuit Breaker Lockouts: Specially designed devices to secure valves (gate, ball, butterfly) in the closed position or fix a breaker toggle in “off.” They’re crucial for isolating pressure/flow and electrical circuits.
Cable Lockouts: Versatile for locking multiple valves or bigger handles. A cable threads around various points, then locks in place.
Group Lock Boxes: Lets you place all isolation keys inside a Group Lock Box, and each worker attaches their padlock. Perfect for large teams or multiple energy sources.

A best practice is to install lockout stations at strategic points in the workplace so locks, tags, and devices are always readily available. This minimises excuses and ensures consistency.

7. Case Studies & Examples

Worst-Case Incidents

Unfortunately, Lockout Tagout failures have led to severe injuries and fatalities in Australia. For example:

Conveyor Fatality: A Queensland worker was killed when he tried to clear a jam while the conveyor’s drive shaft remained energised. A proper lockout would have prevented the shaft from rotating.
Mining Hydraulic Release: In one case, incomplete isolation of a hydraulic press led to a sudden pressure release that fatally injured a worker. Stored energy in the system was not bled off or locked out.
Tag-Only Near Miss: A technician tagged a compressor but did not apply a lock. Another worker overlooked the tag and powered the compressor on. Fortunately, no one was inside it at the time, but it was a close call illustrating that tags alone cannot physically stop re-energisation.

Regulators often find that these tragedies occur because procedures were unclear, workers weren’t properly trained, or no physical lock was used on an accessible control.

Best-Practice Example

At a major food processing plant, a fully documented Lockout Tagout program ensures every piece of equipment has a specific isolation checklist. Before maintenance:

The machine is shut down through its normal controls.
All energy sources (electrical supply, pneumatic lines, steam valves) are identified and isolated using valve lockouts and circuit breaker lockouts.
Each technician places their personal padlock and tag on the isolators or on a lock box system if there are multiple lock points.
A designated person tests the start button to confirm no power remains.

No one removes their padlock until they personally verify their part of the job is complete and the area is clear. This approach eliminates human error or assumptions. The result? Zero lockout-related injuries over multiple years.

Conclusion

From these examples, it’s clear that Lockout Tagout saves lives. Yes, it requires discipline and training to implement effectively. But the alternative—risking fatal accidents and legal consequences—is far worse. Whether you’re running a mine, a construction site, or a small manufacturing workshop, Australian WHS laws expect you to have robust Lockout Tagout policies, procedures, and training in place.

Next Day Safety is proud to support workplace safety by providing a comprehensive range of Lockout Tagout equipment. From safety padlocks and tags to group lock boxes and valve lockout devices, we’re here to help Australian businesses comply with regulations and keep their teams safe.

Remember: No one should ever be hurt by a machine that unexpectedly starts or releases energy. Implementing Lockout Tagout is a straightforward yet powerful way to achieve that goal.