Many injuries on jobsites happen when equipment starts unexpectedly or stored energy is released while someone is working on it. Electrical circuits, hydraulic lines, pneumatic systems, rotating machinery, and even gravity can create dangerous energy sources. If that energy is not properly isolated, a machine can start up, move, or release pressure while someone is inside the danger zone.
This toolbox talk covers the basics of lockout tagout (LOTO), including when it must be used, how crews should recognize uncontrolled energy hazards, and what to do before servicing, repairing, or clearing jams on equipment. The goal is simple: make sure equipment cannot start until the person working on it is safely clear.
Why This Matters
- Unexpected startup can trap, crush, cut, or electrocute workers.
- Stored energy in springs, hydraulics, air lines, or elevated loads can release suddenly.
- Simply shutting off a switch does not guarantee equipment cannot restart.
- Multiple trades working around the same equipment increases the risk of someone turning it back on.
- Proper lockout tagout protects the worker performing the service work.
Common Hazards
- Equipment being serviced without power sources fully isolated.
- Someone restarting machinery because they believe the work is finished.
- Hydraulic or pneumatic pressure still stored in lines or cylinders.
- Gravity hazards such as elevated blades, buckets, or suspended materials.
- Electrical panels or disconnects not properly locked and tagged.
- Workers attempting to clear jams or adjust equipment while it is still energized.
- A second power source feeding the same equipment that workers did not identify.
Safety Checklist
Before Work Begins
- Identify every energy source connected to the equipment.
- Shut down the equipment using the normal stopping procedure.
- Isolate energy sources such as electrical disconnects, valves, or breakers.
- Apply personal locks and tags to prevent re-energizing.
- Release or block stored energy including pressure, tension, or elevated loads.
- Verify isolation by attempting to start the equipment using normal controls.
- Make sure everyone working on the equipment has their own lock applied.
During Work
- Keep locks and tags in place until the work is completely finished.
- Never remove another worker’s lock unless proper procedures are followed.
- Stay aware of nearby workers who may also be affected by the lockout.
- Do not bypass guards or safety devices unless the equipment is properly locked out.
- Communicate clearly with the crew before testing or restarting equipment.
- Ensure tools, parts, and workers are clear before removing locks.
Crew Talking Points
- What equipment on today’s job could require lockout tagout?
- Where are the disconnects, breakers, or valves that isolate those systems?
- Who is responsible for applying locks during maintenance or repairs?
- Have we identified all forms of stored energy on the equipment we are working around?
- What steps should we take before removing locks and restarting equipment?
- Does anyone have concerns about equipment that could start unexpectedly today?
Stop Work If
- You cannot identify all energy sources connected to the equipment.
- Locks or tags are missing from equipment being serviced.
- Someone attempts to start or energize equipment that is locked out.
- Stored energy has not been released or controlled.
- You are asked to service or adjust machinery without proper lockout procedures.
- There is confusion about who placed locks or who is still working on the equipment.
Final Reminder
If equipment can move, start, or release energy, it must be locked out before anyone works on it. One lock can prevent a serious injury.
| Crew Member Name | Signature | Date |
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