Energy sources in construction sites can pose serious hazards to workers, potentially resulting not only in injuries and harm but possibly even fatal incidents. To prevent these occurrences in construction sites and comply with OSHA regulations, proper lockout/tagout procedures are absolutely critical.
Whether you're a business owner, facility manager, or safety manager, the safety of your workers should always be your most important priority. Having a plan in place is critical to the success of any safety program. Machinery doesn’t even have to be in operation to present a possible hazard. As long as the equipment has a connection to electricity, water, compressed air, or other energy sources that enable its functions, a potential hazard exists. Workers responsible for equipment maintenance and care, or those nearby, must be made aware of any risks.
Table of Contents
- Step 1 - Document Procedures for Equipment
- Step 2 - Notify All Users
- Step 3 - Locate All Energy Sources
- Step 4 - Shut Down the Machine
- Step 5 - Disconnect the Energy Sources (Primary and Secondary)
- Step 6 - Verify the Lockout
- Step 7 - Restart the Machinery
- Lockout/Tagout Supplies Available from Zoro
Lockout/Tagout Steps
To create an effective lockout/tagout program, your organization needs to have specific steps in place. Here, we'll take a closer look at the initial steps you need to take to ensure safety at the jobsite. Each step is essential to the procedure and serves as a way to keep workers safe on the job. For more detailed information, see OSHA's lockout/tagout information and requirements.
Step 1 - Document Procedures for Equipment
First, you need to identify all equipment that requires lockout/tagout procedures. Your documentation should also note the location of each piece of equipment in your facility. Then, define the safe and correct shutdown and restarting processes. This explanation should be step by step, indicating all of the energy sources. Be very exact and don't allow for any ambiguity or misunderstanding.
Step 2 - Notify All Users
If your equipment is going down for maintenance, any impacted employees will need to know about the downtime immediately. Provide information about the date(s) and time(s) with an estimate of expected downtime.
Step 3 - Locate All Energy Sources
In the documentation for the equipment, study all the energy sources. Find them on the machinery and ensure everything matches and is the same. If you find any discrepancies, communicate them to people in charge before proceeding. Such issues could be the result of documentation that hasn't been properly updated.
Step 4 - Shut Down the Machine
Next, it’s time to use the instructions for shutting down the machine. These instructions should be explicit and detailed in outlining what to disconnect or what buttons to push. These should be exact actions to take in sequential order. Follow instructions as written without any deviations.
Step 5 - Disconnect the Energy Sources (Primary and Secondary)
Once the machine is shut down, go back to the areas you identified as energy sources. Carefully disconnect all of them per the instructions. This can include power, water, gas, air, or others. There should be someone responsible for the machinery leading this effort. (NOTE: This will not necessarily be the same person who performs the repairs or service.)
After the primary sources are completely disconnected, consider any secondary ones. For example, there could be trapped heat, fumes, or tension that present additional hazards. Address all of these as well before proceeding.
Step 6 - Verify the Lockout
Now that you’ve disconnected all energy sources, you must verify the lockout. You’ll do this by trying to start the equipment, ensuring that no one is nearby. If it doesn’t start, your lockout process was successful. Return all switches to the off position. Then connect your lockout or tagout device to the equipment. Now it’s not possible to move or start it.
The lockout or tagout will remain in place across shifts if necessary. At shift change, the arriving employees will need to be notified.
Step 7 - Restart the Machinery
After the work is complete, it’s time to get the equipment back online. Follow the documented procedures for restarting the machinery. Be sure to do so in the appropriate sequence. Additionally, make physical adjustments to any of the equipment that may incur discharge once you reconnect the energy sources.
Conclusion
Although these steps will serve as helpful reminders, you should always ensure that your construction sites and other places of work are fully in compliance with OSHA's lockout/tagout standards. These critical lockout/tagout procedures will need updates—even possibly more than the annual review OSHA recommends. You’ll need to add to your documentation when you purchase new equipment, for example, or if existing machines go through a retrofit. You may also learn new things while going through the procedure and those insights can improve your documentation, helping to keep future teams safer on the job.
Lockout/Tagout Supplies Available from Zoro
Are your lockout and tagout procedures up to date? If not, it’s a great time to give them some attention. If you find you need some new supplies, we can help. You can find a variety of lockout/tagout solutions at Zoro.
Product Compliance and Suitability
The product statements contained in this guide are intended for general informational purposes only. Such product statements do not constitute a product recommendation or representation as to the appropriateness, accuracy, completeness, correctness, or currentness of the information provided. Information provided in this guide does not replace the use by you of any manufacturer instructions, technical product manual, or other professional resource or adviser available to you. Always read, understand, and follow all manufacturer instructions.