Different Types of Lockout Safety Padlocks in LOTO Industry

Machine-related fatalities are caused due to unexpected release of hazardous energy. Effective Lockout Tagout procedures protect workers from the harmful effects of hazardous energy release, securing and isolating all energy sources. The Lockout Tagout operation necessitates the use of safety measures to restrict the flow of potentially harmful energy. Safety padlocks are detachable locks with a fixed side and an openable side meant to go through Lockout Tagout devices like hasps or Energy Isolating Devices like valves, isolators, etc. Safety padlocks are a key aspect of all Lockout Tagout procedures.

How do they improve safety?

Lockout Padlocks secure the Lockout device in place, preventing its movement and thus preventing the flow of hazardous energy. According to OSHA, a lockout padlock attached to a machine can only be removed by the employee who locked it in the first place. This ensures maximum worker safety and averts accidents due to miscommunication, shift changes or hurried procedures. Each authorised personnel has control over the energy supply; thanks to lockout safety padlock. When a lock and a tag are used together, the level of physical protection that is offered to employees against the release of hazardous energy is at its highest.

Significance of LOTO Padlocks in Lockout Tagout?

Lockout Padlocks are a key aspect of Lockout Tagout safety procedures, without which the safety protocols are incomplete. A safety padlock makes sure that the Lockout device can only be removed by the authorised employee, preventing accidental machine start-up. Safety padlocks are even more significant during group Lockout procedures, as each employee is responsible for his own safety.

Lockout padlock along with an identifying tag ensures that the employee who attached their personal lock, is the only one who can remove it when the maintenance is complete.

How to choose the right padlock according to a specific location, environment, usage, department, and the company’s internal safety policies and procedures.

It might feel daunting and overwhelming to pick among the enormous range of safety padlocks that are available in the market. There are a host of Lockout padlocks in different sizes, materials, shapes, etc., and you might not know where to start looking. Some are designed for high security, while others have weather protection and are better used outdoors. Choosing the right padlock depends upon several factor, including where and how you want to use it or your company’s safety policy requirements.

Maybe the insurance company has asked for maximum safety padlock or perhaps you just want the peace of mind that your machine has been reasonably secured. Our comprehensive guide gives you a basic understanding of the different types of padlocks to help you make the right choice for your facility.

OSHA Standard

A safety padlock safeguards the lives of industrial workers, so it is required to be high quality to withstand the harsh conditions of your industrial environment. A heavy-duty, high security, weatherproof, Lockout lock should only be used for Lockout Tagout purposes. Employees must only be able to remove locks with extreme force using specialised tools, such as bolt cutters or other metal-cutting instruments, as opposed to utilising a key or combination.

OSHA requires safety padlocks provided by the employer to be durable, standardised, substantial, and identifiable, i.e. -

• Be able to withstand long-term exposure to extreme environmental conditions and be resistant to chemicals.
• Have standard colour, shape, or size within the facility or group.
• Be Hand attachable, self-locking, and non-releasable with a minimum unlocking force. They should be substantial enough to prevent their removal without the use of excessive force.
• Indicate the name of persons using the tools and other identifiable details such as padlock numbering, metal tagging, logos, department labels, etc.

Lockout Padlock Types: Based on Material

Choosing the suitable lock body material depends on the intended use environment. By doing your research in advance, you may choose a reliable lock to be used frequently in the predicted environment. Here is a list of most commonly used Lockout Padlocks along with their advantages.

Steel Lockout Padlocks - The hardened steel padlocks are high durability Safety padlocks which can withstand aggressive physical abuse and prevent tampering. Steel lockout padlocks are typically used in higher security applications and are often chrome or zinc-plated to help resist corrosion.

Nylon Lockout Padlocks - These de-electric and lightweight nylon padlocks are non-conductive, non-sparking and ideal for their use on Electrical Panels. A fully insulated nylon body padlock with a nylon shackle is the best safety padlock for preventing electrocution and arc flashing.

Aluminium Lockout Padlocks - Non-magnetic and non-sparking aluminium padlocks are not only compact and lightweight but also chemical and corrosion resistant. Ideal for challenging conditions, these durable and ultra-lightweight Lockout locks are generally used in light security situations. The aluminium bodies are often anodized in different colours, allowing colour coding of lock systems.

Stainless Steel Lockout Padlocks - Corrosion-resistant stainless-steel padlocks are highly durable and easy to use. These are weatherproof safety padlocks perfect for outdoor protection against moisture and generally hold up to the elements better than solid steel.

Brass Lockout Padlocks - Completely spark-resistant brass padlocks are ideal for use in inflammable or explosive environments. Both the inside and outside of these inexpensive safety padlocks are non-corrosive, which allows for use around salt water and other corrosive environments. More durable than some of the other padlocks, these don’t shatter when impacted with a hammer but are not as tamper-resistant as heavier steel padlocks.

Lockout Safety Padlock Types: Based on Body/Shackle

Padlock Body - The solid part of the padlock which contains the locking mechanism is the padlock body. There are generally two types of padlock bodies i.e. long body and short body. Long body padlocks are handy and provide an easy grip for quick application by the authorised employee. On the other hand, short body padlocks are compact and are used in areas where there is not a lot of space for bulky padlocks. These are also ideal for group lockout and multiple-padlock situations.

Padlock Shackle - Padlock shackles are available in varying lengths and diameters, but they are generally categorized into two types. Similar to the Padlock body, Padlock shackles are also available in two sizes - long and small. The short shackle padlock is not only compact but also provides extra protection as it can prove to be difficult for the bolt-cutters or other tools to cut through the shackle. Long shackle padlocks are designed with increased locking area for Lockout purposes where the Lockout device or energy isolating point is bulky and cannot be locked using a small shackled padlock.

Cable Shackle - A cable Lockout padlock is a unique and customizable design for locking multiple isolating points at the same time using a single padlock. These safety padlocks are equipped with a cable which can be maneuvered through multiple isolation points/ Lockout devices on a panel, securing them in place.

LOTO Padlock Types: Based on Locking Mechanism (Feature - Key Retaining)

According to OSHA, ‘One Key, One Lock’ mechanism should be followed for every Lockout Tagout procedure, but there are still a few keying options available in the market. Keyed locks are the safest and cheapest option for an effective Lockout Tagout implementation. You can choose from these options according to the policy and procedural requirements of your company.

Key Different - Each padlock comes with its own unique key. This key cannot open any other padlocks from the provided set. It follows OSHA’s one lock, one key guideline.

Key Alike - All the padlocks in the set have the same locking mechanism, meaning they all can be opened using any of the keys provided along the padlock set. This option is ideal when one authorised employee is responsible for the Lockout application on multiple isolation points, and he is the sole employee with access to keys.

Key Different + Master Key - This keying option is ideal where the management is required to unlock the padlocks in case of emergency. Along with unique and padlock-specific keys, a master key which can open all of the padlocks in the acquired set is provided. A master key should only be used in case the authorised employee cannot unlock his padlock due to unforeseen reasons.

E-Square Lockout Safety Padlocks:

E-Square understands the importance of a successful Lockout Tagout procedure, that is why we have the widest range of Lockout Tagout products available for your facility. If you are looking for high-quality and long-lasting safety padlocks, then look no further than our Lockout Padlock selection with innovative and unique products designed for each and every industry, with more than 48,000 key combinations. Our selection includes de-electric padlocks, unique premier padlock series, cable padlocks and many more. Whatever your requirements may be, we are sure to have a Great Padlocking solution for you.

Lockout Padlock Customization:

E-Square is the No.1 manufacturer and supplier of all Lockout Tagout devices with the highest quality devices designed to protect the lives of your workers. Customised padlocks, specially made for your facility, increase the effectiveness of your LOTO procedures along with productivity.

We can customise your own set of safety padlocks, unique to your safety procedures. Colour-coded Padlocks help employees be organized and ID the equipment. Each colour can represent a specific department or particular employee. Whether you want them colour-coded according to your department or want your company’s logo on the padlocks, we can customise a set of numbered padlocks for you. These numbered padlocks go along with numbered keys and key chains for an organised and quick safety process.

Conclusion

Although Padlocks are a vital part of Lockout Tagout procedures, employee safety is not found in a single item, such as a tag or a lock; rather, it is found in a comprehensive programme that involves the use of safety measures, appropriate processes, and thorough training, all while ensuring accountability.

Employees will be sufficiently protected by a system that utilizes padlocks if these safety guidelines are followed and the employer complies with the other Lockout Tagout related requirements of the standard. It is time to employ an effective Lockout Tagout safety program with adequate LOTO products to ensure the safety and well-being of all employees. And last but not the least, compromising with the quality of LOTO Padlock is non-negotiable…so be sure to opt for only the best quality padlocks with maximum key-combination making them almost impossible to be operated with any other key.