Lockout tagout kit: what's in one, what OSHA requires, and how to choose

Last updated 2026-07-09

What is a lockout tagout kit and what does OSHA actually require?

A lockout tagout kit is a grouped set of physical devices that authorized employees use to isolate machinery from its energy sources before they work on it. The kit usually lives in a portable bag or a wall station so everything sits in one place when a worker needs it.

OSHA's Control of Hazardous Energy standard, 29 CFR 1910.147, covers the procedure and hardware side of lockout/tagout for general industry.^[1] The standard says employers must provide energy-isolating devices capable of being locked out, give each authorized employee their own lock, and de-energize and verify equipment before service begins. What it never does is name a vendor or a SKU.

The standard's plain language, at 29 CFR 1910.147(c)(5)(ii), states: "Lockout devices and tagout devices shall be singularly identified; shall be the only devices used for controlling energy; shall not be used for other purposes." That one sentence is why a dedicated kit matters. Pull locks from a shared bucket or grab whatever's handy, and you're already out of compliance.

For most small businesses, the kit is the fastest way to meet the hardware rules without an engineering study. You assemble or buy one that covers every energy type in your building, then train workers on which device goes on which isolation point. Simple in concept. Messy in practice if you skip the equipment survey first.

A full lockout tagout program has several layers: a written energy control program, equipment-specific procedures, training records, and annual inspections. The kit is only the physical hardware layer.

What's included in a standard lockout tagout kit?

Kit contents vary by manufacturer, but a general-purpose lockout/tagout kit built for 29 CFR 1910.147 compliance usually holds the devices below.

Device	Purpose
Safety padlocks (keyed different)	One per authorized employee, the primary lockout device
Hasp (multi-lock hasp)	Lets multiple workers lock the same isolation point during group lockout
Circuit breaker lockouts	Fit over standard single-pole or double-pole breakers
Electrical plug lockout	Covers 110V or 220V cord plugs so equipment can't be re-energized
Ball valve lockout	Clamps over ball valve handles in the open or closed position
Gate valve lockout	Adjustable for different pipe diameters
Cable lockout	Flexible steel cable to lock irregular shapes or multiple points at once
Danger tags and ties	Nylon ties or plastic-coated tags with a "Do Not Operate" warning
Tag holders	Keep tags visible and attached to the device
Carry bag or station	Keeps everything organized and portable

An electrical lockout tagout kit adds items built for panels: breaker lockouts in several sizes, plug lockouts, and a cable lockout rated for the configurations common in that building.^[2] Run 480V three-phase systems or knife-blade disconnects, and a basic electrical kit won't cover you. You'll need specialized devices on top.

Pneumatic and hydraulic equipment needs its own additions: pneumatic lockout valves, pressure gauge bleeder ports, sometimes push-button lockouts for pneumatic start buttons. A shop with both electrical panels and compressed air lines needs a kit that answers both.

One thing kits almost never include: the written energy control program and the equipment-specific procedures. You still build those yourself. If you want a fast path through the paperwork, SafetyFolio's safety program generator produces a compliant energy control program in about 15 minutes instead of days of drafting.

How serious is the hazard that lockout tagout kits are designed to prevent?

OSHA estimates that proper lockout/tagout programs prevent about 120 fatalities and 50,000 injuries a year in general industry.^[4] That 120-fatalities figure comes straight from OSHA's own analysis behind 29 CFR 1910.147 and has been cited in enforcement documents for decades. The Bureau of Labor Statistics counted 164 fatal occupational injuries in 2022 from contact with objects and equipment, a category where hazardous-energy failures show up often.^[3]

The money risk is real too. OSHA's maximum penalty for a serious violation is $16,550 per violation as of 2024, and a willful or repeated violation can reach $165,514 each.^[5] Lockout/tagout sits among OSHA's top-ten most-cited standards year after year, so inspectors look for it on purpose. A missing or thin kit is easy to spot on a walkthrough.

The injury pattern tells you what kit you actually need. Most serious incidents come from unexpected machine startup, release of stored energy (springs, pressure, gravity), or contact with electrical energy during maintenance. Each scenario maps to a different device in the kit.

What are the different types of lockout tagout kits and which one do you need?

Four practical categories cover almost every small business.

General-purpose kits handle the widest range of energy: electrical, pneumatic, hydraulic, and mechanical. They're a good start for a shop with mixed equipment. Expect $80 to $250 for a decent pre-assembled bag kit from a reputable supplier.^[2]

Electrical lockout tagout kits focus on panel breakers, plugs, fuses, and disconnects. They fit places where nearly all hazardous energy is electrical: a small commercial kitchen, a data center, a light assembly shop. Figure $40 to $120.

Valve-focused kits cover gate, ball, and plug valves. They're common in water treatment, HVAC, chemical processing, and food production, anywhere pneumatic and hydraulic lines carry stored pressure.

Personal lockout kits are small pouches for a single authorized employee: one padlock, a few tags, maybe a couple of breaker lockouts. These supplement a facility-wide station instead of replacing it.

Here's the honest answer on which you need. Do the energy source survey first. Walk every piece of equipment your workers maintain or clean and list every energy type present: electrical, pneumatic, hydraulic, gravity or stored mechanical, thermal, chemical. Then match devices to isolation points. Only after that walk can you tell whether the $89 kit on a shelf covers your hazards or whether you need a custom set.

Kit choice also drives OSHA training. Authorized employees have to be trained on the exact devices they'll use, so pick the hardware before you write the training.

How do you build your own lockout tagout kit instead of buying pre-assembled?

Building your own makes sense when your equipment has odd isolation points, when a pre-assembled kit carries 15 things you'll never touch, or when you need to match lock colors to departments.

Start with the padlocks. Buy individually keyed locks (not keyed alike) in a count that matches your authorized-employee headcount, plus a few spares. Brady and Master Lock both sell safety padlocks rated for lockout. Each lock should survive its environment and be removable only with a key or deliberate destruction.

Add one multi-lock hasp rated for at least six locks. Even a tiny shop benefits. The hasp is cheap insurance for group lockout.

For electrical isolation, get breaker lockouts sized to your panel brands. Sizes are not universal. A lockout that fits a Square D QO breaker won't fit an Eaton BR. Bring photos of your panel or the breaker dimensions when you order.

For pneumatic lines, add at least one cable lockout (the steel cable threads through valve handles, hose fittings, and other irregular shapes) plus ball valve lockouts in the sizes you actually have.

Add tags. OSHA requires tags that warn against energizing, and they must be legible and understandable.^[1] Standard red "Danger, Do Not Operate" tags on tear-resistant material with a rated attachment (something stronger than string) are the norm.

Put it all in a dedicated bag, box, or station. Label it. Keep it in a known spot. A kit nobody can find in an emergency is as useless as no kit.

Total for a self-built kit covering a small electrical and pneumatic shop: roughly $60 to $180 depending on lock count and valve sizes. Less than a single OSHA penalty.

What do OSHA inspectors actually look for when they audit lockout tagout compliance?

OSHA's lockout/tagout standard generates some of the highest-frequency citations in general industry inspections.^[9] When a compliance officer walks your floor, they check far more than whether you own a kit. They check the whole program.

The audit usually covers whether you have a written energy control program, whether you have equipment-specific procedures for each machine with unexpected-energization potential, whether authorized employees have been trained and that training is documented, whether you've run annual audits of your procedures, and whether your physical devices actually fit the hazards present.

The hardware check is fast. An inspector may ask an authorized employee to demonstrate a lockout on a specific machine. If the worker can't find the right device for that isolation point, or grabs one that doesn't fit, that's a potential violation even if you own a beautiful kit on the wall.

Common hardware findings: locks keyed alike (not allowed for individual control), tagout-only programs on equipment that could be locked (OSHA prefers lockout where feasible), and missing group lockout procedures. Less often, inspectors find kits that handle electrical isolation but ignore the pneumatic lines on the same machine.

One letter of interpretation is worth knowing. OSHA has stated that employers must provide the necessary lockout/tagout devices at no cost to employees, and a worker's personal preference for their own lock doesn't relieve that duty.^[6] Your people can carry a preferred padlock, but you still have to provide compliant devices if they don't.

If you've never run an inspection-readiness check, the incident report habits that feed OSHA recordkeeping also expose near-miss patterns around equipment energization. Read those records before an inspector does.

How do you train employees to use a lockout tagout kit correctly?

29 CFR 1910.147(c)(7) names two groups who need training: authorized employees who perform lockout/tagout, and affected employees who work near it but don't perform it.^[10] The requirements differ for each.

Authorized employee training must cover recognition of hazardous energy sources, the type and magnitude of energy in the workplace, and the methods for isolation and control. In plain terms, a worker should be able to look at any machine they service, name every energy source, and put the correct device from the kit on each isolation point.

Affected employee training is lighter. They need to understand that they must not restart or re-energize equipment under lockout. They don't need to know how to apply the devices.

Training on the kit itself has to be hands-on. Walk authorized employees through every device. Show them which breaker lockout fits your panel, how the cable lockout threads through a valve handle, how the hasp works for group jobs. Paper-only training won't hold up under 1910.147, and it won't protect anyone.

OSHA also requires retraining when you have reason to believe an employee has lost the required knowledge or skill, or when an energy control procedure changes.^[1]

Document all of it: training dates, employee names, topics covered, who delivered it. An OSHA 30 course covers hazard control broadly, but it's no substitute for the equipment-specific lockout training your workers need on your specific machines.

How often do you need to inspect and update your lockout tagout kit and procedures?

The standard requires an annual audit of energy control procedures. 29 CFR 1910.147(c)(6) states: "The employer shall conduct a periodic inspection of the energy control procedure at least annually to ensure that the procedure and the requirements of this standard are being implemented."

That annual inspection must be done by an authorized employee other than the one using the procedure. Call it a peer review: someone who knows the equipment and the standard confirms the procedure is being followed and still matches how the equipment is set up.

For the physical kit, workers inspect devices before each use, and you run a formal inventory at least once a year. Locks disappear. Tags fade. Valve lockouts crack under temperature cycling. If a device fails mid-lockout, the whole control is gone.

Update the kit when equipment changes. Add a machine with a different breaker brand, and buy the right breaker lockout before it goes into service, not after the first maintenance cycle. Equipment changes that affect energy control also mean revising the written procedure and re-training affected employees.

One honest caveat on timing. Most small businesses do their annual inspection on paper and skip the live walk-through with an employee demonstrating the procedure. That walk-through is the part inspectors check. If your "annual inspection" is a supervisor signing a form, it's probably not enough.

What's the difference between lockout and tagout, and when does your kit need which?

Lockout physically stops a machine from being energized by placing a lock and lockout device that holds an energy-isolating switch, valve, or plug in the safe position. Tagout uses a warning tag to say the equipment shouldn't be energized, but with no physical lock behind it.

OSHA's preference is clear: use lockout whenever the energy-isolating device can be locked.^[1] Tagout-only is allowed only when the equipment design can't accept a lock, and even then the employer has to show that tagout gives "full employee protection" equal to lockout.

In practice, new equipment is almost always lockable. Older equipment with older disconnect designs sometimes can't take a hasp or lockout device without modification. That's where tagout procedures come in, and they demand extra protection: removing and isolating circuit elements, blocking controls, opening additional disconnects.

For your kit, this means every kit needs tags, no matter how much you rely on lockout. Tags go on the lock during a lockout, and they're the primary device in a tagout. Run out of tags and the whole program stops.

Some small businesses run tagout-only to dodge the cost of lockout hardware. That's a compliance risk and a safety risk. If your isolating devices can be locked, buy the lockout devices. The hardware costs far less than the penalty for a tagout-only program on lockable equipment.

How much does a lockout tagout kit cost, and what should you budget for a full program?

Costs split into two buckets: hardware and program development.

For hardware, expect the ranges below.

Kit type	Approximate cost range
Basic personal lockout pouch (1 worker)	$20 to $50
Electrical lockout tagout kit (pre-assembled)	$40 to $120
General-purpose kit (10-20 devices)	$80 to $250
Large facility station with 50+ locks	$300 to $800
Custom-built kit for complex equipment	$150 to $500+

These reflect typical catalog pricing from major safety suppliers as of 2024.^[2] Prices move with lock count and with whether you buy individually keyed locks. Keyed-different locks cost more than keyed-alike, but keyed-alike locks don't meet the individual-control requirement, so pay for the keyed-different ones.

Program development is where small businesses lowball themselves. Hire a consultant to write your energy control program and equipment-specific procedures, and expect $500 to $2,500 depending on facility size and equipment count. Write it yourself using OSHA templates and the cost is time, roughly 8 to 20 hours for a complete program with procedures.

OSHA's website gives free compliance assistance, including sample energy control programs.^[2] Those templates are a legitimate starting point. You still have to customize them for your equipment.

Do the penalty math. A serious OSHA violation for a missing or inadequate lockout/tagout program costs up to $16,550 per violation.^[5] A kit plus a written program costs a small fraction of that, and it prevents injuries that cost far more in workers' comp, lost productivity, and human suffering.

Are there special requirements for electrical lockout tagout kits vs. other energy types?

Electrical energy gets the most attention because it's the most common energy type in almost every building, and because it can kill with no visible warning. An electrical lockout tagout kit has to cover every point where electrical energy can enter equipment: circuit breakers, disconnects, plug connections, and control circuits.

Electrical work brings an overlap between 29 CFR 1910.147 (lockout/tagout) and 29 CFR 1910.333, the electrical safety standard for general industry.^[7] When qualified electrical workers do electrical work (not merely service a machine that happens to be electrical), 1910.333 applies too. The two standards work together, not against each other.

The practical line: 1910.147 covers servicing and maintenance of machines (replacing a motor, cleaning inside a machine, clearing a jam). 1910.333 covers electrical work itself (working on live panels, troubleshooting circuits). If your maintenance workers are non-qualified employees working on machinery that happens to run on electricity, 1910.147 is your standard and an electrical kit is your hardware answer.

For qualified electrical workers doing electrical work, NFPA 70E (developed by the National Fire Protection Association) adds arc flash protection and approach distances that go beyond any kit.^[8] An electrical lockout/tagout kit is necessary for arc flash hazard work but not sufficient.

Other energy types each need their own answer. Pneumatic lines need valve lockout devices and often a pressure bleeder. Hydraulic systems need pressure relief before lockout. Mechanical energy (springs, suspended parts, gravity-loaded equipment) needs blocking and restraint that no lock provides on its own.

How do you set up a lockout tagout station vs. a portable kit, and which is better for small businesses?

A lockout tagout station is a wall-mounted board or cabinet at a fixed spot, usually near the equipment it serves or in a central maintenance area. Workers go to the station, take what they need, and return it after the job. A portable kit is a bag or box that travels with the worker.

For small businesses, the honest answer is both, set up for your layout.

Got one or two major machines that get serviced often? Mount a dedicated station near each one, stocked with the exact devices for that machine's isolation points. Workers stop hunting for hardware.

Workers moving between areas or buildings? A portable kit in a bag wins. The technician carries what they need, which suits anyone covering a whole facility.

Many small shops go hybrid: a central station with shared devices (hasps, tags, spare locks) plus individual pouches for each authorized employee holding their personal lock and a few universal items.

Station versus kit is also a training question. A labeled station makes it easier to train new workers and easier to catch missing items during inventory. A portable bag puts the burden on the worker to know the full contents and run their own pre-job inventory.

If you're writing or updating your energy control program and want a faster path through the documentation, SafetyFolio's safety program generator produces customizable energy control programs you can adapt to your equipment and station layout.

Frequently asked questions

Does OSHA require a lockout tagout kit specifically, or just lockout devices?

OSHA's 29 CFR 1910.147 requires energy-isolating devices capable of lockout, singularly identified locks for each authorized employee, and warning tags. The standard doesn't require a "kit" as such. A pre-assembled kit is simply the most practical way to meet those hardware requirements and keep devices organized and accessible.

Can a small business use a tagout-only program to avoid buying lockout hardware?

Only if your energy-isolating devices genuinely cannot be locked, which is rare with modern equipment. OSHA requires lockout whenever the isolating device can accept a lock. A tagout-only program on lockable equipment is a violation and leaves employees less protected. A basic lockout kit costs far less than the minimum OSHA penalty for this violation.

How many padlocks do I need in my lockout tagout kit?

At minimum, one individually keyed padlock per authorized employee, meaning everyone who performs lockout/tagout gets their own lock. Keyed-alike locks don't meet individual-control requirements. Add a few spares for new hires and replacements. For group lockout, you also need at least one multi-lock hasp rated for your largest likely team size.

What's the difference between an electrical lockout tagout kit and a general lockout tagout kit?

An electrical lockout tagout kit focuses on electrical isolation: circuit breaker lockouts, plug lockouts, and cable lockouts for disconnects and panels. A general-purpose kit adds valve lockouts (ball, gate), pneumatic devices, and broader hardware. If your facility has only electrical hazards, the electrical-specific kit may be enough. Mixed-energy facilities need the general-purpose version plus energy-specific add-ons.

Do lockout tagout devices expire or need to be replaced on a schedule?

OSHA sets no fixed replacement schedule, but it requires devices durable enough to withstand the environment and last the length of the hazard control period. Inspect devices before each use and replace any showing cracks, corrosion, deformation, or fading that makes them unreadable. Do a full kit inventory at least once a year during your required energy control procedure audit.

Can workers share one lock in a lockout tagout kit?

No. 29 CFR 1910.147 requires each authorized employee to apply their own personal lock to the energy-isolating device. Sharing a lock defeats the individual-control principle: if one worker finishes and removes the shared lock without knowing another is still in the danger zone, the equipment can be re-energized. Each person gets their own keyed-different lock.

What happens if I need to remove a lock when the employee who placed it is not available?

OSHA requires a specific procedure for removing a lock when the placing employee is unavailable. It must include verifying the employee is off-site, making a reasonable effort to contact them, and ensuring they know the lock was removed before they return. Document the removal. This should be rare; if it's common, your procedures have a gap.

Are lockout tagout requirements different for contractors working in my facility?

Yes. Under 29 CFR 1910.147(f)(2), when outside contractors perform service or maintenance, the host employer and contractor must inform each other of their lockout/tagout procedures and ensure each understands and follows them. Don't assume a contractor's kit and procedures match yours. Get their energy control program before work starts and confirm it's compatible.

What color should lockout tags and padlocks be?

OSHA mandates no specific color, but it requires lockout/tagout devices to be standardized within a facility by color, shape, or size, and to be the only devices used for energy control. Most facilities use red for lockout and orange for caution tags. Pick a standard and hold to it. Inconsistent colors create confusion about which devices are lockout devices versus other operational tags.

Do I need equipment-specific lockout procedures in addition to the kit?

Yes. 29 CFR 1910.147(c)(4) requires written procedures for each piece of equipment with more than one energy source, or where the de-energization sequence matters. These document exactly which isolation points to lock, in what order, and how to verify a zero energy state. The kit provides the tools; the procedure tells workers how to use them on that specific machine.

What is the OSHA penalty for not having a lockout tagout program?

A serious violation of 29 CFR 1910.147 carries a maximum penalty of $16,550 per violation as of 2024. Willful or repeated violations can reach $165,514 each. Lockout/tagout is one of OSHA's most-cited standards, so the odds of citation during an inspection run high. A complete program, hardware plus written procedures plus training records, is the only reliable way to avoid citation.

Can I use cable locks instead of dedicated breaker lockouts in an electrical lockout tagout kit?

Cable lockouts work well for irregular shapes and can thread through some breaker handles, but they aren't always the most secure fit for panel breakers. Dedicated breaker lockouts clamp over the breaker and are harder to defeat. OSHA requires that lockout devices hold the isolating switch in a safe position; if a cable lockout does that securely for your panel design, it can be compliant. When in doubt, use the device made for the application.

How do I document that I conducted the required annual lockout tagout inspection?

The record must identify the machine or equipment inspected, the date, the employees involved, and the name of the authorized employee who performed the inspection. OSHA requires no specific form. Many businesses use a simple checklist capturing those four elements plus any deficiencies found and corrective actions taken. Keep records available for at least three years to cover a typical inspection look-back period.

Sources

1. OSHA, 29 CFR 1910.147 Control of Hazardous Energy (Lockout/Tagout): Requires energy-isolating devices capable of lockout, individually identified lockout devices for each authorized employee, warning tags, and annual inspection of energy control procedures.
2. OSHA, Control of Hazardous Energy compliance assistance page: General-purpose lockout/tagout kits from major safety suppliers range approximately $80 to $250; OSHA provides free compliance assistance and sample programs.
3. Bureau of Labor Statistics, Injuries, Illnesses, and Fatalities program (Census of Fatal Occupational Injuries, 2022): BLS counted 164 fatal occupational injuries in 2022 attributed to contact with objects and equipment.
4. OSHA, Lockout/Tagout Fact Sheet (Publication 3120): OSHA estimates that proper lockout/tagout programs prevent approximately 120 fatalities and 50,000 injuries each year in general industry.
5. OSHA, Penalties page: OSHA's maximum penalty for a serious violation is $16,550 per violation and for willful or repeated violations is $165,514 as of 2024.
6. OSHA, Standard Interpretations letters (Control of Hazardous Energy): OSHA has stated employers must provide the necessary lockout/tagout devices at no cost to employees, and a worker's personal preference lock does not relieve that responsibility.
7. OSHA, 29 CFR 1910.333 Selection and Use of Work Practices (Electrical Safety): Electrical safety in general industry is governed by both 29 CFR 1910.147 (for equipment servicing) and 29 CFR 1910.333 (for electrical work itself); the two standards are complementary.
8. National Fire Protection Association, NFPA 70E Standard for Electrical Safety in the Workplace: NFPA 70E adds arc flash protection and approach distance requirements for qualified electrical workers beyond what a lockout/tagout kit alone provides.
9. OSHA, Most Frequently Cited Standards: 29 CFR 1910.147 (Control of Hazardous Energy) is consistently among OSHA's top ten most frequently cited standards in general industry inspections.
10. OSHA, 29 CFR 1910.147(c)(7) Training Requirements: Authorized employees must be trained on recognition of hazardous energy, magnitude and type of energy, and methods of isolation and control; affected employees must understand not to restart locked-out equipment.