Not long ago, we had to service a high-pressure steam system at our facility and brought in two outside contractors to handle the job. These contractors, accustomed to their company’s simpler tagging method, began work before they were fully brought into our group LOTO procedure. Midway through the task, I saw the group lockbox was missing their personal padlocks and halted the job immediately.
It turned out they had locked out the equipment using their own system, without notifying our primary authorized employee or coordinating with the team. Though no one was injured, the close call triggered a full review of contractor onboarding and reinforced the need for strict group lockout tagout compliance across all crews.
Key Takeaways
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Group lockout tagout is required when more than one worker services equipment to ensure every person has control over their own safety before re-energization.
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OSHA 1910.147(f)(3) mandates group LOTO procedures that give each worker protection equal to personal lockout.
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Group lockout devices like lockout boxes and hasps are used to secure energy sources and ensure accountability in group LOTO.
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A written group lockout procedure helps standardize steps, enforce roles, and meet OSHA compliance requirements.
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Manage shift changes and contractor work with updated controls to prevent unexpected energization or miscommunication.
What Is a Group Lockout Tagout?
Group lockout tagout is a safety procedure for controlling hazardous energy during servicing or maintenance when more than one employee or multiple crews, shifts, or contractors are involved. Unlike individual lockout tagout, where one worker applies and removes their lock, group LOTO involves a structured approach using a group lockbox or a multi-lock hasp. A primary authorized employee oversees the process, and each worker places their personal lock on the group lockbox or hasp, ensuring collective control and preventing re-energization until all locks are removed.
Group Lockout Tagout OSHA Requirements
The OSHA 29 CFR 1910.147 standard, also known as the Control of Hazardous Energy (Lockout/Tagout), sets the rules for protecting workers during equipment servicing and maintenance. While the standard outlines general lockout tagout procedures, it also includes special instructions for situations involving multiple workers.
These requirements for group lockout tagout are found in 29 CFR 1910.147(f)(3). In group settings, the same lockout tagout steps apply as in individual LOTO procedures, but with a few added rules to address coordination and accountability among team members. 29 CFR 1910.147(f)(3)(ii) specifies four key requirements that must be built into this group lockout procedure:
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Designate a primary authorized employee who is responsible for overseeing the entire lockout operation. This individual is responsible for the overall coordination and the locks that safeguard the crew.
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Maintain real-time awareness of who is exposed to hazardous energy. The primary employee must be able to identify at any moment which workers are actively involved in the task.
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Appoint an overall coordinator if multiple crews, departments, or contractors are involved. This person, also an authorized employee, ensures consistent protection across all groups and locations.
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Require each authorized employee to apply and remove their own personal lock or tag on the group lockout device, such as a group lockbox or hasp. This step reinforces individual control and accountability throughout the job.
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Roles and Responsibilities in Group Lockout
In group lockout tagout, clear roles and responsibilities are what keep the process safe, organized, and compliant. The two main roles are:
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Responsibilities |
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Primary Authorized Employee |
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Authorized Employee |
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A group lockout procedure is only as strong as the people assigned to carry it out. When roles, especially those of authorized employees and contractors, aren’t clearly defined and followed, you’re one misstep away from an accident. Everyone involved needs to understand not just what to do, but who’s responsible for what.
What Devices Are Typically Used in Group Lockout?
Group Lockout Box
Group lockout box is used to store the keys to all the locks applied to the equipment's energy-isolating devices. Once the equipment is locked out, the keys are placed inside the lockbox. Each authorized employee then applies their personal lock to the outside of the box. The lockbox cannot be opened until every employee has removed their personal lock, ensuring that no one is exposed to hazardous energy before the job is complete.
Lockout Hasps
Lockout hasps allow multiple padlocks to be attached to a single isolation point. This is useful when more than one person needs to lock out the same energy source. The hasp is placed through the isolating device (such as a switch handle or valve), and then each worker attaches their padlock through the hasp.
LOTO Padlocks
Personal LOTO padlocks give each worker individual control over hazardous energy during group lockout. When using a group lockout box, these padlocks secure the box that contains the keys to the equipment locks. Each worker places their personal padlock on the box, meaning the keys and thus the ability to restore energy, remain inaccessible until every padlock is removed.
In addition to standard equipment, other group lockout devices, such as the adjustable cable lockout, can be used to secure multiple breakers, valves, or hard-to-access panels.
Step-by-Step Group Lockout Procedure
As outlined in 29 CFR 1910.147(f)(3)(i), OSHA requires that group lockout tagout procedures provide each employee with the same level of protection they would have if using their own personal lock. Follow this step-by-step procedure
1. Identify Energy Sources
Before beginning the lockout, identify all energy sources connected to the equipment, including electrical, hydraulic, pneumatic, and mechanical types. Review the equipment-specific energy control procedures to understand how to safely isolate these sources. Notify all employees of the planned shutdown and explain why the lockout is necessary.
2. Shut Down Equipment
The equipment should be shut down using standard procedures provided by the manufacturer or internal protocols. The primary authorized employee leads this shutdown and ensures it is done safely. This step helps eliminate the possibility of unexpected movement or energy release.
3. Isolate Energy Sources
All energy sources must be physically isolated using valves, disconnects, or breakers. The primary employee confirms that every source feeding the equipment is completely disconnected. Mechanical energy may also need to be restrained or released.
4. Apply Group Lockout Tagout
The primary authorized employee places the initial lockout device, such as valve locks, push button lockout, and breaker locks, on each isolation point and secures the keys in a group lockout box. This box remains locked and under their control.
The group device prevents re-energization until all personal locks are removed.
In setups using lockout hasps, each personal lock is placed directly on the hasp at the isolation point. Since only the person who applied a padlock can remove it, the equipment can't be re-energized until all workers are clear.
5. Attach Personal Locks to Group LOTO Devices
Every authorized employee places their personal lock and tag on the group lockout device. This ensures each individual retains control over their own safety and confirms they are actively working on the equipment. Personal locks can only be removed by the person who applied them.
6. Verify Energy Isolation
Before work starts, the system must be tested to ensure it is fully de-energized. This critical step is also known as lockout tagout tryout (LOTOTO). This may include using test instruments and trying to operate the machine to confirm it won’t start. Verification must be documented or communicated to all involved employees.
7. Perform Maintenance or Service
Maintenance or servicing work begins only after all authorized employees have applied their locks and the system is verified safe. The primary authorized employee must keep track of who is exposed to hazardous energy at any time. This step remains active until all tasks are completed.
Throughout the job, the primary authorized employee ensures ongoing communication with all crew members. Any changes in personnel or work scope must be tracked and managed. A sign-in sheet or tagboard on the group lockout box can help monitor participation.
8. Remove Locks After Work Completion
Once the work is finished, each authorized employee must remove their personal lock. No one is allowed to remove another person’s lock except in emergencies and with proper documentation. The primary authorized employee removes their lock last, after confirming that the equipment is safe to return to service.
9. Restore Equipment to Service
After all locks have been removed and the area is clear, the primary authorized employee restores energy by reopening isolation devices. Guards must be in place, and affected employees should be notified before re-energizing. The equipment is then tested or restarted according to normal procedures.
How Are Shift Changes Handled in Group Lockout?
During shift changes, the primary authorized employee must account for outgoing and incoming workers. Each new authorized employee must apply their own lock before the departing worker removes theirs, maintaining continuous protection. This handoff prevents the equipment from being re-energized during a transition.
Common Group LOTO Mistakes and How to Avoid Them
Even with a solid procedure in place, mistakes in communication, training, and equipment use can weaken the effectiveness of a group lockout tagout program. Recognizing common mistakes and knowing how to prevent them can make the difference between a safe operation and a serious incident:
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Miscommunication Among Team Members: Poor coordination between team members or shifts can lead to someone unknowingly working on energized equipment. Always use written lockout checklists, visual indicators like sign-in logs, and verbal confirmations to maintain awareness of who is actively working.
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Improper Training: Workers who don’t fully understand their responsibilities under group lockout procedures may skip steps or apply locks incorrectly. Training should be job-specific, scenario-based, and include hands-on demonstrations.
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Incorrect Use of the Group Lockout Box: Not placing keys properly or not locking the box once all keys are inside compromises the entire system. Assign a primary authorized employee to manage and oversee the entire lockout process.
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Failure to Audit Procedures Regularly: Equipment changes over time, and if the group lockout procedure isn't updated, it can become outdated and unsafe. Review and audit group LOTO procedures regularly to catch issues before they lead to incidents.
What Training Is Required for Group Lockout?
To meet OSHA standards and promote safe practices, training for group lockout tagout must include the following key areas:
LOTO Fundamentals
Group Lockout Concepts
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- What group lockout is and why it’s used
- When a group lockout procedure is required, instead of individual LOTO
- How a group lockout box functions to secure keys and centralize control
Role-Based Responsibilities
Step-by-Step Training on Group LOTO Procedure
Equipment and Tools
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- How to use group lockout box, personal locks, hasps, tags
- How to use a group lockout box
- Tagout devices and documentation
Communication Protocols
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- Sign-in/sign-out log procedures
- How employees are notified of lockout status
- Protocols for adding or removing personnel during lockout
Hands-On Practice
Emergency and Special Cases
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- Lock removal when an employee is unavailable
- Coordination with contractors or other crews
- Dealing with stored/residual energy
To keep employees current with safe group lockout practices, retraining must be conducted as needed. It is required whenever there are changes in job roles, equipment, or procedures, or when inspections, incidents, or employee performance reveal gaps in knowledge or compliance.
Group Lockout FAQs
Who completes a group lockout?
A designated primary authorized employee coordinates the group lockout, but each authorized employee must apply and later remove their own personal lock to maintain individual control.
Should group lockout/tagout procedures be documented?
Yes, OSHA requires written procedures that clearly outline the steps, roles, and devices used in group lockout/tagout to ensure consistency and compliance.
What advantage does a lockbox provide during a group lockout?
A group lockbox centralizes the keys to energy-isolating devices, allowing each worker to secure the box with their personal lock and ensuring no re-energization until all workers have finished.
How many locks can be attached to a group lockout box?
Most lockboxes are designed to accommodate 6 to 12 locks directly, but additional capacity can be added using lockout hasps or extension devices.
What happens if a worker leaves during a group lockout?
If a worker leaves before the job is complete, only they can remove their personal lock; if not available, a specific removal procedure, following OSHA guidelines and with documented authorization, must be followed.