How to Use a Lockout Hasp: A Complete Guide for Lockout Tagout Safety

Workplace accidents caused by unexpected machine startup remain one of the most serious safety risks in industrial environments. To prevent such incidents, companies around the world rely on Lockout Tagout (LOTO) procedures. One of the most important tools in a LOTO system is the lockout hasp.

Understanding how to use a lockout hasp correctly is essential for ensuring worker safety, regulatory compliance, and effective energy isolation. This guide explains what a lockout hasp is, why it is used, and provides a step-by-step explanation of proper lockout hasp usage in real industrial scenarios.

What Is a Lockout Hasp?

A lockout hasp is a LOTO device designed to allow multiple workers to apply their personal lockout padlocks to a single energy-isolating point. It is commonly used when more than one person is involved in servicing or maintaining equipment.

Lockout hasps are typically made from:

• Steel (often with vinyl-coated handles)

• Aluminum

• Non-conductive plastic (for electrical environments)

They feature multiple lock holes, enabling each worker to attach their own lock.

Why Is a Lockout Hasp Important?

A lockout hasp ensures that equipment cannot be re-energized until every worker has completed their task and removed their personal lock.

Key Safety Benefits

• Prevents accidental startup of machinery

• Ensures personal control of hazardous energy

• Supports group lockout procedures

• Improves accountability and safety communication

Using a lockout hasp is a best practice in compliance with OSHA Lockout Tagout standards (29 CFR 1910.147) and other international safety regulations.

When Should You Use a Lockout Hasp?

You should use a lockout hasp whenever:

• More than one worker is performing maintenance or repair

• Multiple shifts are involved in servicing equipment

• Contractors and employees are working together

• Group lockout is required for complex systems

Typical applications include electrical panels, valves, circuit breakers, and machinery control switches.

How to Use a Lockout Hasp: Step-by-Step Guide

Step 1: Identify the Energy Source

Before using a lockout hasp, identify all hazardous energy sources, such as:

• Electrical energy

• Mechanical energy

• Hydraulic or pneumatic pressure

• Thermal or chemical energy

Ensure the equipment is fully shut down according to standard operating procedures.

Step 2: Isolate the Energy

Operate the energy-isolating device to place the equipment in a safe OFF position. This may include:

• Turning off a circuit breaker

• Closing a valve

• Disconnecting a power switch

Verify that the machine is completely de-energized.

Step 3: Apply the Lockout Hasp

Attach the lockout hasp to the energy-isolating point. The hasp physically prevents the device from being moved back to the ON position.

Ensure the hasp is securely fitted and cannot be removed without unlocking.

Step 4: Attach Individual Lockout Padlocks

Each worker involved in the task must:

• Attach their personal lockout padlock to the lockout hasp

• Keep the key in their possession

This step ensures that no one can restart the equipment unless every lock is removed.

Step 5: Add Lockout Tags

Attach a lockout tag to each padlock or to the hasp. The tag should clearly state:

• The worker’s name

• Department or company

• Reason for lockout

• Date and time

Tags improve communication and reinforce accountability.

Step 6: Verify Zero Energy State

Before beginning work:

• Attempt to start the equipment

• Confirm that it does not operate

This verification step is critical and should never be skipped.

Step 7: Perform Maintenance or Service Work

With the lockout hasp and all padlocks securely in place, workers can safely perform maintenance, repairs, or inspections.

No lock should be removed until the individual who applied it has completed their task.

Step 8: Remove Locks and Restore Energy

Once work is completed:

• Each worker removes their own padlock

• The lockout hasp is removed only after the last lock is taken off

• Energy is restored according to proper startup procedures

Common Mistakes to Avoid When Using a Lockout Hasp

Even with proper equipment, incorrect usage can compromise safety.

Common Errors

• Sharing keys or using non-personal locks

• Failing to use a hasp during group work

• Removing another worker’s lock

• Skipping verification of zero energy

Avoiding these mistakes is essential for maintaining a safe LOTO program.

Types of Lockout Hasps and Their Applications

Steel Lockout Hasps

• High strength and durability

• Often feature vinyl-coated handles for better grip

• Suitable for heavy industrial environments

Non-Conductive Lockout Hasps

• Made from plastic or nylon

• Ideal for electrical applications

• Reduce risk of electric shock

Aluminum Lockout Hasps

• Lightweight and corrosion resistant

• Suitable for general industrial use

Choosing the right lockout hasp depends on the environment and type of energy being controlled.

Lockout Hasp vs Lockout Tagout Alternatives

Lockout hasps remain one of the simplest and most effective tools for group lockout safety.

Best Practices for Lockout Hasp Use

• Always use a lockout hasp for group maintenance tasks

• Assign one personal lock per worker

• Use color-coded padlocks for identification

• Train employees regularly on LOTO procedures

• Inspect lockout hasps for wear or damage

Consistent application of these practices strengthens overall workplace safety.

Conclusion

Understanding how to use a lockout hasp correctly is a fundamental part of an effective lockout tagout program. Lockout hasps provide a simple yet powerful solution for ensuring that hazardous energy remains isolated until every worker is safe and ready.

By following proper procedures—identifying energy sources, applying the hasp, using personal padlocks, and verifying zero energy—organizations can significantly reduce workplace accidents and ensure compliance with safety regulations.

Whether in manufacturing, electrical maintenance, oil and gas, or construction, lockout hasps play a critical role in protecting lives and maintaining a safe working environment.