Lockout Padlocks

Keyed different means every padlock has a unique key that opens only that lock — the standard for individual personal lockout, since OSHA's fundamental principle is that only the applying employee holds the key. Keyed alike means a batch of locks all share one common key, useful for group lockout boxes where any authorized worker in the group needs access. Master keyed adds a separate supervisory key that opens every lock in a set without needing each individual key, used for documented emergency lock removal.

Color coding is a common way to visually organize a lockout program — assigning colors by department, by authorized employee group, or by hazard type lets anyone doing a lockout audit or walk-down quickly identify who applied a lock or which system it belongs to without checking a tag on every lock.

Nylon or other non-conductive body padlocks are specified for electrical lockout applications, since a metal-bodied lock near live or potentially live electrical components introduces an unnecessary conductive path. Check the specific application against NFPA 70E and your facility's electrical safety program requirements.

Only following the employer's documented lock removal procedure, which OSHA 1910.147 requires for situations where the authorized employee who applied the lock isn't available to remove it themselves — this typically involves verification that the employee is not performing the work, a specific process to remove the lock, and notifying the employee before they resume work. A master key makes physical removal possible, but the procedure, not just the key, is what makes it compliant.

Shackle length and diameter need to clear whatever hasp, breaker lockout device, or multi-lock hasp the padlock will pass through — standard shackle lengths cover most single-point lockout devices, while long-shackle padlocks are used for group lockout hasps or larger isolation devices that need more clearance.