ABUS 2ALHB/40-75 Lockout Padlock — Long Shackle Keyed Alike

The ABUS 2ALHB/40-75 keyed-alike lockout padlock with a 3-inch (75mm) long shackle solves one of the most common practical problems in LOTO programs: the energy isolation point that a standard-shackle padlock simply cannot reach. Valve handwheels, thick multi-lock hasps, large gate valves, and bulky equipment handles often have clearances that exceed the 1" to 1.5" clearance a standard safety padlock shackle provides. The 2ALHB/40-75's 75mm shackle clears these obstacles cleanly, keeping your lockout procedure compliant without requiring improvised workarounds that undermine program integrity. The keyed-alike configuration makes this model the right choice for supervisors, safety officers, and group lockout coordinators who need one key to operate multiple locks.

Key Features

• 3-inch (75mm) long shackle — reaches valve handles, thick hasps, and bulky equipment lockout points
• Keyed-alike (KA): all locks in a set share the same key for supervisor/safety officer master-key access
• Aluminum body — lightweight, corrosion-resistant, and non-conductive for electrical applications
• 40mm body width — standard LOTO padlock form factor compatible with most lockout hardware
• ABUS commercial-grade construction — engineered specifically for safety lockout, not repurposed security hardware
• OSHA 29 CFR 1910.147 compliant for use in written lockout/tagout programs
• Bright safety color for visual identification on multi-lock hasps

Product Specifications

Detailed Description

Standard safety padlocks are engineered for the most common lockout scenario — a hasp jaw that accepts a 1" to 1.5" shackle clearance. But real industrial facilities have equipment that was not designed with LOTO hardware in mind. Large gate valves, pneumatic isolation valves with oversized handles, thick gang hasps that carry six or more padlocks simultaneously, and equipment cabinets with deep-set hasp loops all create situations where a standard shackle simply will not close around the lockout point. Forcing an undersized shackle into an oversized fitting or looping chains through valve handwheels is not a compliant workaround — it introduces failure points and creates ambiguity in the written LOTO procedure.

The ABUS 2ALHB/40-75 addresses this directly with a 75mm (approximately 3-inch) long shackle. This extended clearance passes cleanly through the thick jaws of heavy-duty multi-lock hasps, wraps securely around oversized valve handle spokes, and reaches through the deep-set loops of larger equipment enclosures. The lock body itself remains 40mm — standard width — so it mounts on the same lockout stations and fits in the same lock pouches as the rest of your LOTO inventory. Only the shackle is extended.

The keyed-alike configuration is equally deliberate. Under OSHA 1910.147, each authorized employee must apply their own personal padlock, and that lock should open only with their key. But LOTO programs also require a documented emergency exception procedure for situations where an employee leaves the site without removing their lock. The safety manager or shift supervisor needs a reliable, controlled way to access those locks. A keyed-alike set allows a designated supervisor to hold one master key that opens every lock in the KA set — a practical administrative tool when used within a properly documented program.

Keyed-alike locks are also the correct choice for group lockout procedures where a single coordinator applies multiple locks to different isolation points on the same equipment and then removes them all at the end of the procedure. Rather than managing separate keys for each point, the coordinator's single key operates all locks in the set, reducing the administrative burden of multi-point isolation without compromising the exclusivity of the lockout.

The aluminum body construction keeps the lock lightweight enough for daily carry while resisting the corrosion that shortens the service life of steel-body locks in wet, chemical, or outdoor environments. The non-conductive body is particularly valued in electrical switchgear rooms and substation work where incidental contact with lock surfaces near energized components is a practical concern during the verification phase of the lockout procedure.

ABUS builds the 2ALHB series to the same commercial-grade standards as the rest of the 74/40 safety padlock family, with resistance to picking and forced-entry attack that ensures only intentional, authorized removal is possible.

Compliance and Standards

• OSHA 29 CFR 1910.147 — Control of Hazardous Energy (Lockout/Tagout)
• Suitable for use in LOTO procedures governed by NFPA 70E (electrical safety in the workplace)
• Meets OSHA substantive requirements for durability, identifiability, and exclusiveness of lockout devices

Real-World Benefits

Maintenance technicians who regularly encounter thick hasps or large valve handles cite the long-shackle padlock as the solution that finally standardized their LOTO procedure at problem isolation points. Rather than noting exceptions in written procedures or using improvised hardware, the 3-inch shackle makes the procedure clean and consistent. Safety auditors reviewing written LOTO programs consistently flag improvised workarounds; switching to a long-shackle lock eliminates the finding.

Supervisors who carry a keyed-alike set report significantly reduced time in emergency lock-removal situations. With a single key on their person, a shift supervisor can clear a forgotten lock at the end of a maintenance window without a full lock-cutting and re-issuance procedure, as long as the action is documented in accordance with the facility's written LOTO program.

Applications and Use Cases

• Large gate valve and globe valve lockout on process piping where handwheels are thick or oversized
• Multi-lock hasp applications where 6–12 padlocks share a single hasp and shackle clearance is tight
• Supervisor master-key sets for emergency lock removal under documented LOTO exception procedures
• Group lockout coordinators who apply and remove multiple locks across an equipment isolation sequence
• Electrical substation and switchgear lockout where equipment enclosure loops are deep-set
• Petrochemical and refinery facilities with non-standard valve configurations

Related Products

• Shop All Lockout/Tagout Equipment
• ABUS 74/40 Lockout Tagout Padlocks — 10-Pack (Keyed Different)
• Personal Protective Equipment (PPE)
• Brady SafeKey Aluminum LOTO Padlock — Keyed Different
• American Lock A1107R Red Safety Lockout Padlock

Frequently Asked Questions

What is the difference between keyed-alike and keyed-different for LOTO padlocks?

Keyed-different (KD) means each padlock has its own unique key — only the worker who applied it can remove it, which is the standard requirement for personal-lock LOTO compliance. Keyed-alike (KA) means multiple locks all open with the same key, used for supervisor master-key access or group lockout procedures where one person controls all locks.

Why does OSHA 1910.147 allow keyed-alike locks if each worker must have their own lock?

OSHA requires that each authorized employee's lock be exclusive to that employee. A KA set used by one person (for example, a coordinator applying multiple locks to different isolation points) is compliant because one person holds the key. KA locks used across multiple workers would not satisfy the exclusivity requirement unless used within a documented group lockout procedure with a coordinating supervisor.

How does the 75mm shackle compare to a standard padlock shackle?

A standard safety padlock typically has a 25mm to 38mm shackle clearance. The 75mm shackle on the 2ALHB/40-75 provides roughly double to triple that clearance, making it suitable for oversized valve handles, thick multi-lock hasp jaws, and deep-set equipment enclosure loops where a standard shackle will not close.

Does the long shackle make the lock less secure?

A longer shackle does increase the exposed steel surface area, which is a general consideration in security applications. For LOTO use, the primary requirement is that only the authorized keyholder can remove the lock — which the keyed-alike mechanism ensures. ABUS uses hardened steel shackles throughout the 74/40 family, including the long-shackle variant.

Can I mix ABUS 2ALHB/40-75 long-shackle locks with standard ABUS 74/40 locks on the same hasp?

Yes. The 40mm body width is consistent across the ABUS safety padlock line. A multi-lock hasp will accept both standard and long-shackle variants simultaneously, which is common in facilities that reserve long-shackle locks for specific workers or specific isolation points.

Is this lock suitable for outdoor or wet environments?

The aluminum body resists corrosion well in most outdoor and damp environments. For extreme chemical or saltwater exposure, check ABUS specifications for the appropriate protective coating option. The hardened steel shackle may show surface rust in prolonged salt or acid exposure — inspect periodically as part of your LOTO equipment maintenance program.

What colors is the 2ALHB/40-75 available in?

ABUS offers the 2ALHB/40-75 in multiple safety colors to support facility color-coding programs. Contact WCSafety for current color availability or to request a specific color for your department or trade assignment.