ANSI ASSP Z244.1-2016 (ANSI ASSE Z244.1-2016) PDF

Full title and description

ANSI/ASSE (now ANSI/ASSP) Z244.1-2016 — The Control of Hazardous Energy: Lockout, Tagout and Alternative Methods. This consensus standard establishes requirements and specifies the use of lockout (the primary method), tagout or documented alternative methods to control hazardous energy associated with machines, equipment or processes that could cause harm to personnel during construction, installation, servicing, maintenance, inspection, testing, troubleshooting, cleaning or dismantling activities.

Abstract

This standard provides a framework for developing and implementing hazardous energy control programs. It defines responsibilities, required procedures, machine and equipment design considerations, training, and verification measures for lockout, tagout and alternative methods. Alternative methods are permitted when justified by a risk assessment and shown to provide effective protection, while lockout is emphasized as the primary control method. The document includes extensive annexes with examples, sample programs and industry-specific guidance.

General information

• Status: Superseded by ANSI/ASSP Z244.1-2024 (the 2016 edition was later maintained as R2020 and is listed as superseded).
• Publication date: 2016 (original 2016 edition; a reaffirmation/revision entry R2020 appears in later records).
• Publisher: American Society of Safety Professionals (ASSP), formerly American Society of Safety Engineers (ASSE).
• ICS / categories: Occupational safety and safety of machinery (ICS group 13 — occupational safety / safety of machinery).
• Edition / version: ANSI/ASSE Z244.1-2016 (recorded with a revision notations as R2020 in distribution listings).
• Number of pages: Approximately 128 pages (typical published PDF length shown in product listings).

Scope

Applies to machines, equipment and processes where unexpected energization, startup, release of stored energy, or the actions of persons could result in harm. The standard covers when and how to apply lockout, tagout or documented alternative methods, how to perform hazard identification and risk assessment, program management, required procedures for isolation and verification, training and auditing, and provisions for group and complex lockout/tagout situations. It is intended for use across industries and includes industry-tailored annexes and examples.

Key topics and requirements

• Definitions and roles: authorized employees, affected employees, program administrators and supervisors.
• Design considerations: requirements for energy-isolating devices and design guidance to facilitate safe isolation.
• Hazardous energy control program: written program elements, procedures, periodic inspection and audit requirements.
• Primary control methods: lockout (preferred), tagout (limitations and application), and documented alternative methods based on risk assessment.
• Risk assessment and the hierarchy of controls as the basis for authorizing alternative methods (detailed guidance and annexes).
• Group lockout/tagout and complex multi-source energy control procedures; management of change and permit systems.
• Training, verification of isolation, procedures for removal of locks/tags when personnel are absent, and program records.
• Annexes: sample programs, procedures, industry-specific examples (packaging, pharmaceutical, plastics, printing, steel, semiconductor, robotics, etc.).

Typical use and users

Used by safety professionals, EHS managers, maintenance and engineering teams, facility managers, machine designers, auditors and compliance officers to develop, implement and audit hazardous energy control (LOTO) programs. Employers use the standard to align corporate procedures with consensus best practices and to supplement regulatory requirements. Training providers and consultants commonly reference the standard for course content and program templates.

Related standards

Commonly referenced documents and regulatory materials include OSHA's Control of Hazardous Energy regulation (29 CFR 1910.147) and OSHA guidance on LOTO, machine safety and related consensus standards; ANSI/ASSP Z244.1-2024 (the later edition that supersedes the 2016 text); ANSI B11 series on machine safeguarding (for example B11.19); ANSI/ASSP Z117.1 on confined spaces; and other machinery safety standards such as IEC/ISO machinery safety documents and NFPA/industry-specific guidance. These standards are often used together to build a comprehensive machinery and maintenance safety program.

Keywords

lockout, tagout, hazardous energy control, LOTO, alternative methods, risk assessment, machinery safety, hazardous energy, program management, training, group lockout, energy isolating device

FAQ

Q: What is this standard?

A: ANSI/ASSE Z244.1-2016 is a consensus standard that sets out requirements and guidance for controlling hazardous energy through lockout, tagout and documented alternative methods to protect personnel from unexpected energization or release of stored energy.

Q: What does it cover?

A: It covers program elements, responsibilities, machine/equipment design considerations, procedures for isolation and verification, training, group lockout/tagout, management of change, and industry-specific examples and templates in its annexes. It allows alternative methods when justified by risk assessment, while emphasizing lockout as the preferred method.

Q: Who typically uses it?

A: Safety and EHS professionals, maintenance and engineering staff, machine designers, trainers, auditors and employers implementing or improving hazardous energy control (LOTO) programs.

Q: Is it current or superseded?

A: The 2016 edition has later maintenance/revision entries (R2020 in distribution records) and is listed as superseded by ANSI/ASSP Z244.1-2024; users should consult the 2024 edition for the most current consensus requirements and any substantive changes.

Q: Is it part of a series?

A: It is part of the broader body of machinery and occupational safety consensus standards and is commonly used alongside ANSI/ASSP machine safety standards (B11 series), confined-space standards (Z117.1), and relevant international machinery safety standards and regulatory guidance.

Q: What are the key keywords?

A: Lockout, tagout, hazardous energy, LOTO, alternative methods, risk assessment, machinery safety, energy-isolating device, program, training.