A lockout kit is a set of safety devices used to isolate energy sources and prevent equipment from being turned back on during maintenance. It ensures that once power is switched off, it stays off until work is complete.
Often referred to as Lockout Tagout (LOTO), the system combines physical locks and safety devices combined with tags that identify who applied them. As a result, it protects workers from one of the most serious risks — unexpected energisation.
What Does “Lockout Tagout” Specifically Mean?
Lockout Tagout, or LOTO, refers to the process of isolating an energy source or damaged equipment.
- Lockout physically prevents equipment from being operated
- Tagout communicates who applied the lock and why
While both are important, lockout provides critical physical protection. Therefore, tags should always support — not replace — locks.
Why Lockout Matters for Electrical Safety
When working on electrical systems, isolation alone is not enough. Instead, the real risk is someone restoring power while work is underway.
For example:
- Another worker may unknowingly re-energise equipment
- Isolation points may not be clearly visible
- Stored energy may still exist in the system
Because of this, standards such as AS/NZS 4836:2023 and AS 4024.1603 require lockout procedures.
Safe Work Australia – Managing electrical risks in the workplace
Where Are Lockout Kits Used and Why?
Workers use lockout kits anywhere energy sources need to be controlled.
Most commonly, they are used in:
- Electrical switchboards
- Industrial machinery and equipment
- Maintenance and servicing environments
- Construction and infrastructure sites
Lockout kits can consist of a wide range of devices designed to isolate various site-specific energy sources. As a result, they ensure workers have the right equipment on hand to safely isolate equipment without delays or interruptions to the job.
In addition, many facilities use lockout stations, which are wall-mounted systems that store lockout devices in a central location.
Lockout stations improve visibility and consistency. As a result, teams can quickly access the correct equipment when needed.
How Are Lockout Kits Used in Practice?
A lockout kit supports a structured isolation procedure.
Typically, this process includes:
- Identify all energy sources
- Shut down and isolate the equipment
- Apply lockout devices to isolation points
- Attach personal padlocks and tags
- Verify isolation before starting work
Workers can safely re-energise equipment only after all locks are removed. Therefore, each worker maintains full control over their own safety.
WorkSafe Queensland Electrical Safety Office technical guides
WorkSafe Victoria Isolate, de-energise, lockout and tagout plant
SafeWork NSW Isolation of Plant – Lock-out / Tag-out
SafeWork SA Isolation procedures
WorkSafe WA Isolation of plant/lock-out tag-out
Common Mistakes When Using Lockout Kits
Even with the right equipment, mistakes still happen.
Common issues include:
- Assuming switching off power is sufficient
- Not isolating or verifying all energy sources before lockout
- Failing to use personal locks
- Not tagging clearly or correctly
- Sharing locks between workers
Because of this, teams must follow clear procedures and training when using lockout kits.
What Does a Lockout Kit Include? (Equipment Breakdown)
Lockout kits vary depending on the application. However, they suit different environments and team sizes.
Personal Lockout Kits
- Convenient belt bag for ultimate portability
- Designed for technicians working across multiple sites
- Keeps essential devices accessible at all times
- Mainly used for domestic switchboards
Small Lockout Kits
- Portable and easy to carry
- Includes essential breaker lockouts, padlocks, and tags
- Ideal for single users
- Suitable for domestic or light commercial work
Medium Lockout Kits
- Comprehensive lockout kit
- Includes additional lockout devices and hasps
- Suitable for multiple workers
- Designed for industrial environments
Large Lockout Kits
- Complete electrical lockout kit including valve lockout
- Includes a extensive range of lockout devices
- Ideal for sites with multiple energy sources
- Covers complex industrial applications
Lockout Kits vs Lockout Stations
In practice, teams often use these two solutions together on site.
- Lockout kits → Portable, used by contract workers and teams
- Lockout stations → Fixed, shared access points for large sites
In larger facilities, stations ensure equipment is always available. Meanwhile, kits allow workers to carry what they need.
Choosing the Right Lockout Solution
The right setup depends on your environment.
- Domestic or light work → Small kits or belt bag kits
- Industrial sites → Medium or large kits
- Multi-worker environments → Larger Kits with hasps and multiple lock/valve types*
- Fixed worksites → Lockout stations for shared access
- Multi-worker enviroments also require a Group Lockout Lock Box
If your requirements vary, a combination of kits and stations is often the best solution.
Final Thoughts
Lockout kits are essential for preventing unexpected energisation, one of the most serious risks in electrical work.
However, having a kit is only part of the solution. Instead, teams must use it correctly, consistently, and as part of a structured procedure.
Because of this, when isolating equipment, no one should be able to restore power while work is in progress.