A lockout tag serves as a visual reminder that equipment is under service and maintenance and should not be operated until it's safe. According to OSHA 29 CFR 1910.147(c)(5)(ii)(A), these tags must be durable enough to withstand harsh conditions. If a lockout tag fades, tears, or breaks under harsh conditions, it can lead to serious injuries or violations.
While both plastic and cardstock are commonly used for lockout tagout tags, it's important to consider their differences to choose the best option for your specific needs in controlling hazardous energy.
Key Takeaways
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Lockout tags are attached to energy isolation devices to signal that equipment must not be operated until the lockout device and tag are removed.
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OSHA standard 1910.147(c)(5) requires tagout devices to be durable and not deteriorate in a way that obscures the warning message on the tag.
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A lockout tag that tears, fades, or disintegrates in the field can compromise the message, putting workers at risk.
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Choosing between plastic lockout tags and cardstock tags depends on your work environment, exposure to elements, and the length of time you need the tags to last.
What Does a Lockout Tag Do?
Lockout tagout tags are an essential component of the lockout tagout (LOTO) process used to protect workers from hazardous energy during equipment servicing. These tags are affixed to energy isolation devices, such as safety padlocks, circuit breaker locks, or push button locks, to signal that equipment must not be operated until the lock and tag are removed by an authorized employee.
Lockout tagout tags are not, by themselves, physical barriers that prevent the use of equipment or the release of stored energy. According to the Occupational Safety and Health Administration (OSHA) standard 29 CFR 1910.147(c)(2)(i), tags may only be used in place of lockout devices if the employer can prove that the tag provides equivalent protection. When lockout tagout tags are used without locks, additional safety measures must be in place to ensure protection.
OSHA’s report on the Most Frequently Cited Standards for fiscal year 2023, the Control of Hazardous Energy (Lockout/Tagout) standard ranked sixth, with 2,539 violations, pointing to persistent gaps in energy control practices. Yet, OSHA estimates that full compliance with the standard could prevent approximately 120 fatalities and 50,000 injuries each year.
What Are Plastic Lockout Tags?
Plastic lockout tags are made from durable synthetic materials, typically PVC or polyester, and are designed to withstand tough industrial conditions. These tagout devices are often used in environments with high moisture, extreme temperatures, or exposure to chemicals. The material resists tearing, fading, and smudging, helping the tag remain legible throughout a long maintenance period.
Many lockout tags come with pre-drilled holes reinforced by a brass grommet to prevent tearing during use. To comply with 29 CFR 1910.147(c)(5)(ii)(C)(2), these tags must be secured using a non-releasable attachment, such as a nylon cable tie, with a minimum unlocking strength of 50 pounds. Compared to cardstock tags, plastic lockout tags offer superior durability and a more professional, permanent-looking solution, especially where environmental exposure is a concern. However, these tags are generally more expensive than cardstock.
What Are Cardstock Tags?
A cardstock lockout tag is made from a heavy paperboard material that’s thicker and more durable than regular paper. These lightweight, paper-based tags are a cost-effective option, best suited for short-term use or environments where exposure to moisture, chemicals, or abrasion is minimal.
Some cardstock tags come with a laminated surface to improve resistance to moisture, smudging, and wear. While not as durable as plastic, laminated cardstock offers a middle-ground option for environments that need some added protection without the cost of a full plastic tag.
Comparative Analysis of Plastic and Card Stock Lockout Tagout Tags
The infographic below provides a comprehensive comparison of the primary characteristics exhibited by plastic and cardstock lockout tags to help in selecting the best material for specific lockout tagout procedures:
Use Cases and Applications of Each Material
The best choice between plastic and cardstock lockout tags often comes down to the specific demands of the environment, the duration of the lockout, and the risk level of the equipment involved. Below are examples that highlight when each material is most appropriate.
Example 1: Chemical Plant Requiring Waterproof Tags
At one chemical processing site I worked with, maintenance crews were routinely locking out pumps, mixers, and valves exposed to caustic cleaning solutions and high humidity. Early on, we were using laminated cardstock tags, thinking they’d be “good enough.” They weren’t. Within hours, the tags had absorbed moisture, and the ink started to smudge. One tag tore off entirely when it got snagged on a pipe.
After that incident, we switched to plastic lockout tags. Their durability and chemical resistance eliminated those issues, and we haven’t looked back since. The tags remained legible, attached, and compliant throughout the full duration of our energy control procedures.
Example 2: Routine Maintenance in Commercial Buildings
In contrast, while consulting for a large office complex, I recommended cardstock lockout tags for routine HVAC servicing and lighting work. These were short-duration tasks done indoors, in clean, dry environments. The cardstock tags performed just fine. They were easy to write on, clearly visible, and the team appreciated how lightweight they were.
I’ve also worked with facilities that fall somewhere in between. A food packaging plant I advised used laminated cardstock tags for most of their lockout points. The lamination added just enough resistance to handle daily washdowns without needing the full toughness of plastic. It was a smart, cost-conscious middle-ground solution.
💡 Expert Tip
If you’re ever unsure which tag to choose, test both materials in your work environment for a week. Look at how they hold up. You’ll often find the right answer just by seeing which one still does its job at the end of the shift.
FAQs on Lockout Tagout Tags
What are the tags used in LOTO?
The tags used in LOTO are typically durable, standardized labels attached to lockout devices. They are designed to withstand environmental conditions and must be legible and understandable. These tags often contain specific warnings, instructions, and identification information about the lockout situation.
Are there specific regulations regarding the type of material used for lockout tags?
Yes. OSHA 29 CFR 1910.147(c)(5)(ii)(A) requires that lockout tags be durable, legible, and able to withstand the environmental conditions where they’re used, but it does not mandate a specific material.
How to properly use lock out tags to prevent accidents?
To properly use lock out tags, they must be securely attached to the energy isolation device using a non-releasable attachment and clearly identify the authorized employee who applied them. They should always be used as part of a complete energy control procedure, not on their own, unless specific OSHA conditions are met.
Is plastic or card stock better for outdoor use?
Plastic is better suited for outdoor use due to its resistance to moisture, UV exposure, and temperature changes. Cardstock can degrade quickly in those conditions.
When might card stock tags be a suitable option for lockout procedures?
Cardstock tags are suitable for short-term lockouts in clean, dry, indoor environments where exposure to harsh elements is minimal. They’re a cost-effective option for lower-risk maintenance or servicing activities.