The Ultimate Guide to Lockout Tagout for Australian Workplaces

Summary and Quick Takeaways

Lockout Tagout (often shortened to “LOTO,” but we’ll prioritise saying “Lockout Tagout”) 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.

Table of Contents

  1. Regulations & Standards
  2. When is Lockout Tagout Required?
  3. Policies & Procedures
  4. Industry-Specific Applications
  5. Training & Assessment
  6. Lockout Tagout Equipment
  7. 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:

  1. Shut down and de-energise the plant.
  2. Lock all isolator points with personal padlocks.
  3. Tag the locks with clear identification of who placed them.
  4. 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.

Continue to Page 2 for guidance on When Lockout Tagout is Required and Policies & Procedures.

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