Lockout tags are warning labels used during equipment servicing. These show that a machine or energy source has been isolated and must not be used. The tags also identify who applied the lockout.
Lockout/tagout tags, or LOTO tags, help prevent accidental startups. These tags are used with a lockout device whenever possible.
This guide discusses lockout/ tagout tags, the different types, and their uses. It also discusses fill-out steps, materials, and different tagout violations.
Lockout Tag Requirements Specified by OSHA 1910.147
OSHA 1910.147 calls for a particular legend on each lockout tag. The lockout tag serves as a warning label to a machine that contains some form of energy-isolating device.
The legend must read Do Not Start, Do Not Open, Do Not Close, Do Not Energize, or Do Not Operate.
The tag must also identify the employee who applied it. Lockout/tagout tags must be durable enough to survive the environment where they hang. A tag exposed to oil, heat, or weather cannot fade or crack before the job ends.
When To Use Tagout Alone Instead of Lockout
Tagout alone is allowed only when the equipment has no lockable isolation point. OSHA treats lockout as the primary method for controlling hazardous energy.
A tag communicates a warning, but it does not physically stop equipment from starting. If an energy-isolating device can accept a padlock, tagout alone is not permitted. But when tagout is the only option, the employer must add extra safeguards. These include removing a fuse, blocking a switch, or bleeding down stored pressure.
Safety lockout tags used without a lock still need this extra layer of protection.
What Types of Lockout Tags Does Your Facility Need?
Most facilities need four tag types to cover every maintenance scenario.
Do Not Operate Tags
Do not operate tags are attached directly to a valve handle, breaker, or switch. They tell workers the equipment is off limits until the tag comes off. This is the most common tag used during routine service work.
Danger Tags
Danger tags warn of an immediate hazard, such as exposed wiring or stored pressure. The tags are written in large bold letters in red. Workers must view them as a red stop sign and not a warning flag.
Status Tags
Status tags track the condition of equipment, such as inspected, out of service, or under repair. They help supervisors see equipment history at a glance. Many facilities color code status tags by shift or department.
Custom Tags
Custom tags fit unique hazards that standard templates do not cover. A valve manufacturer might need a tag for torque testing or seat replacement. Custom tags still must follow the same legend and identification rules.
Tag Material Comparison: PVC vs PET-Coated vs PP Composite Film
The proper choice of tag material will depend on climate, exposure to chemicals, and the frequency of handling.
The most commonly used tags include PVC tags, PET-coated tags, and PP composite film tags.
PVC Tags Cost Less But Wear Faster
PVC tags cost the least of the three common materials. They work fine indoors but crack faster in direct sunlight.
PET-Coated Tags Resist Chemicals and UV
PET-coated tags resist chemical splash, UV rays, and moisture better than plain PVC. The coating adds a thin protective layer over the printed text. LOTO tags made from PET hold up well near washdown areas.
PP Composite Film Tags Handle Extreme Cold
PP composite film tags handle extreme cold and repeated flexing without cracking. This makes them a good fit for outdoor valves in northern climates. They cost more than PVC but last through more weather cycles.
How Do You Fill Out a Lockout Tag Correctly?
Filling out a lockout tag ensures that all employees can easily see the details and know what to do. Follow these steps in correctly fill out the tags:
- Fill out a lockout tag with the employee name, date, and reason for lockout.
- Write the name of the authorized employee who applied the device.
- Add the date the tag went on the equipment.
- State the specific reason, such as motor replacement or seal repair.
Remember to use permanent ink, not pencil, so the writing does not smear or fade. Attach the lockout tag to the energy-isolating device itself, not nearby.
Durability and Attachment Requirements: The 50 Pound Pull Test
OSHA requires every tag attachment to survive at least a 50-pound pull test. The rule appears in 1910.147(c)(5)(ii)(C)(2) and sets a minimum unlocking strength.
The attachment must be non-reusable, self-locking, and removable only by hand force. It should perform like a one-piece, all-environment nylon cable tie.
Durability also matters, since a tag must survive heat and chemical exposure for the full job. LOTO tags used outdoors or near heavy vibration need the strongest attachment available.
Danger Lockout – Do Not Operate Safety Warning tagout tags
BD-P02 Hazard Lockout – Do Not Operate Safety Warning Label. Used to alert workers to potential safety hazards.
More DetailsWhat Are the Most Common Tagout Violations?
The most common tagout violations involve shared keys, missing tags, and reused devices. Each removes a layer of protection the standard requires.
Using Master Keys or Shared Locks
A wall of locks with one shared key defeats the purpose of lockout. OSHA requires that only the employee who applied the lock removes it. Shared keys let someone else restart equipment while a coworker still works on it.
Skipping Tags When Lockout Isn’t Possible
Some crews skip the tag entirely when a lock cannot fit the isolation point. A tag is still required even when a lock is not possible.
Reusing Old Tags on New Jobs
Reused tags carry outdated names, dates, and reasons that confuse the next shift. OSHA requires non-reusable attachment devices for this exact reason. A fresh tag for every job keeps the paper trail accurate.
Conclusion
Lockout/tagout tags protect workers only when paired with hardware built for real isolation. Hence, when using these tags, they must be filled out and labelled correctly.
BOZZYS provides lockout/tagout products that have been certified to ISO 9001, ISO 14001, and ISO 45001 standards. The company’s devices are certified under CE, ATEX, and ANSI as well. Sourcing tags and lockout items from one manufacturer that is certified makes audits easier and closes a common gap in LOTO programs.
Frequently Asked Questions (FAQs)
Can a lockout tag be handwritten in pencil?
No. OSHA requires the tag legend and details to stay legible for the full job duration. The pencil smears and fades with handling or moisture. Use permanent markers or pre-printed fields instead.
Do lockout tags need to match a specific color?
OSHA does not require one universal color, but it does require standardized print and format within a facility. Most companies use red or orange for danger and yellow for status.
Can a coworker remove someone else’s lockout tag during an emergency?
Only the employee who applied the tag should normally remove it. In a true emergency, a supervisor may remove it under a documented procedure. This step requires verifying the original employee is safe and unavailable.
