Group Lockout Procedures

Energy Control
English (Canada)

The Problem

When multiple workers are servicing the same piece of equipment, relying on a single lockout device creates serious safety risks. Without proper group lockout procedures in place, there is a danger of accidental re-energization, which can result in severe injuries or fatalities. Today, we’ll discuss how to implement group lockout methods — such as multi-lock hasps and lock boxes — to protect all team members and ensure compliance with Canadian Centre for Occupational Health and Safety (CCOHS) guidelines.

Identify the Hazards

  • Accidental re-energization: One worker may remove a lock thinking the job is done, while others are still working on the equipment.
  • Communication failures: Poor communication between workers may lead to premature lock removal.
  • Inadequate lockout methods: Using a single padlock for a group task increases the risk of someone unknowingly restarting equipment.

    • Safety Practices and Preventative Measures

    Use a Multi-Lock Hasp:

    • Attach the hasp to the energy isolation point.
    • Each team member secures their individual padlock to the hasp.
    • The hasp cannot be removed—and the equipment cannot be restarted—until all locks have been removed.

    Why it works:
    No one can restart the machine while others are still working.

    Use a Group Lock Box:

    • The lead authorized person isolates the equipment and locks out all energy sources using designated locks.
    • The keys to these locks are secured inside a lock box.
    • Each worker places their personal lock on the lock box.
    • The box cannot be opened until the last personal lock is removed.

    When to use it:
    Ideal for complex equipment with multiple isolation points or when multiple workers are involved.

    Ensure Clear Communication:

    • Communicate who is working, what the job is, and when it’s safe to remove locks.
    • Confirm all team members have removed their locks before restarting equipment.

    Real-Life Case or Scenario

    Where possible, use an actual incident that you have experienced or been involved in.

    At a processing plant, a worker removed their lock from an isolation device, mistakenly assuming the task was complete. Another worker remained inside the equipment performing maintenance. Fortunately, a multi-lock hasp prevented the equipment from being restarted, avoiding a serious incident. This highlights the importance of effective group lockout procedures and communication.

    Employee Responsibilities

    • Place your personal padlock on the hasp or group lock box before starting work.
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    • Do not remove your lock until your part of the job is fully complete.
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    • Confirm with the team that all locks are still in place.
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    • Communicate clearly with others involved in the job.

    Employer Responsibilities

    • Provide lockout devices suitable for group work, including multi-lock hasps and lock boxes.
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    • Train workers on group isolation and lockout procedures.
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    • Ensure lockout and isolation procedures are documented and enforced in compliance with applicable Canadian workplace safety regulations and CCOHS guidance.

    Discussion & Questions

    • Have you experienced challenges when using group lockout methods?
    • How could we improve the way we manage shared isolation tasks on-site?

    Commitment/Action Plan

    Let’s commit to applying group lockout procedures on every shared task. Starting today, take responsibility for your padlock and ensure that no equipment is restarted until all locks are removed and the job is confirmed complete.

    Wrap-Up

    Group lockout is about teamwork and communication. Using the correct tools—multi-lock hasps and lock boxes—keeps everyone safe and compliant. Let’s work together to make our site safer.

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    Standards Overview

    Canadian workplace safety regulations require employers to identify and control hazardous energy during maintenance and servicing. Group lockout procedures must ensure all workers are protected from accidental re-energization. Written procedures and worker training are required as part of an employer’s duty of care under applicable provincial health and safety legislation and supported by guidance from the Canadian Centre for Occupational Health and Safety (CCOHS).

    Disclaimer

    “The information provided in this toolbox talk is intended for informational and educational purposes only. It is not a substitute for professional legal, safety, or regulatory advice. The content reflects general best practices and industry standards but may not be applicable to all workplace environments or jurisdictions.

    It is the responsibility of employers, supervisors, and workers to ensure compliance with applicable federal, provincial, and territorial laws, regulations, and standards, including but not limited to those set by the Canadian Centre for Occupational Health and Safety (CCOHS) and relevant provincial occupational health and safety authorities. Site App Pro, its affiliates, agents, or representatives—as well as the authors, presenters, and distributors of this toolbox talk—assume no liability for the use or application of the information provided.

    Participants are strongly encouraged to consult appropriate legal, safety, or regulatory professionals regarding specific workplace concerns or questions. Always adhere to your organisation’s policies and procedures for health and safety and hazard management.

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    Last Updated:
    July 4, 2025