Padlock Keying Options - Case Study and FAQs

We`re all familiar with padlocks, widely used in a all manner of situations to provide reliable security. But managing the keys needed for multiple padlocks can quickly become very challenging. In this post we look at a case study demonstrating the application of master keyed padlock suites and clarify the various padlock keying options available. Anyone who has ever needed to manage and look after keys for multiple padlocks will understand the challenges involved. In domestic, home-based environments people are typically looking after their front door keys, back door keys, car keys, keys to their outbuildings and possibly more. Adding a number of padlock keys to this burgeoning collection isn’t always the most sensible option. In commercial environments, factories, office buildings and other workplaces such as schools and hospitals, security management is even more challenging. Padlock Keying Options - Case Study As a leading supplier of high quality padlocks we routinely support our customers in devising optimal key management strategies that work for them. Here’s a recent, representative example. The Lock and Key Problem Our customer contacted us to discuss a very time consuming problem he needed help with. He worked in a factory that has a high number of doors and cabinets secured with padlocks. These needed to be accessible to both him and many of his colleagues. However, some of the secured resources included dangerous equipment which should only ever be accessible to those with the required safety training. Originally, the number of keys required to secure these facilities was quite small, while the workforce size was still quite low. Management of key allocations to colleagues was relatively simple and he was readily able to keep track of where keys were and ensure only qualified staff could access the secured, dangerous equipment. But as the business developed the workforce expanded and this growth included many more keys, making management and security far more challenging. His initial solution was to clearly label each of the keys so he knew which key matched which padlock. But with constant, day-to-day usage along with the impact of weather, his meticulous key labelling system failed as the labels faded and pealed off, leaving him with a big bunch of unlabelled keys. The security challenge was further demonstrated when some of these important keys were lost and the business didn’t have replacements. The only realistic option in these circumstances was to cut the padlocks to remove them and since some of the padlocks were expensive, high-security locks this wasn’t a simple, or low-cost option. Our customer knew he was spending far too much time attempting to manage a highly insecure key management system that was putting the business at risk and not fulfilling basic security or operational requirements. The Master Suite Solution It was clear that overhauling his key and lock security strategy would save time and money while bolstering security. The cost savings would easily outweigh the losses currently being experienced due to the ineffective, manual key management system. He started by sensibly auditing his current locking requirements, listing all of the doors, cabinets and resources secured with padlocks along with the personnel who needed access to each of them. After discussing his requirements with us he decided upon a master suite system wherein he and just a couple of his more senior colleagues could have keys that opened every lock (grandmaster keys) while other supervisory colleagues could have keys that opened specific groups of locks (master keys) and individual workers were only allocated keys to resources (such as personal lockers) which they had required permissions to access. The key pattern numbers were recorded, enabling lost or damaged keys to be easily replaced. And for added security the key patterns were restricted, which means he was the only member of staff who had permission to get spare keys cut when required. Importantly, this commercial site used a variety of padlock types including shutter-locks, long-shackled padlocks along with weatherproof, marine-grade exterior padlocks. All of these were included in the design of his master suite padlock collection. The Result The result of this much needed attention to padlock security and key management is a practical system that’s saving time and money while providing enhanced, robust security. The numbers of keys required by any staff member has been minimised and the possibility of issues arising due to lost or damaged keys has been mitigated. The padlocking scheme has been future-proofed as any replacement padlocks, required when padlocks wear out, can be ordered based on existing, recorded key patterns. And access to any new cabinets or lockers can be restricted by using only appropriately designated key patterns. Padlock Keying Options - FAQ We often address queries such as: Do I need my padlocks to be keyed alike, keyed differ or master keyed? So we`ve compiled this list of common padlock keying related questions and answers. What does keyed to differ mean? Keyed to differ, or ‘keyed different’, simply means each padlock operates from it`s own unique key pattern. This is the default keying option for most padlocks. ‘Differs’ is a locksmith’s term referring to the number of possible keys for a given lock. The number of key differs relates to various lock design parameters such as the number of pins and lock depth spacings. These give rise to both ‘real’ and ‘theoretical’ number of key differs. For example, a 5 pin lock with 10 depth spacings offers 100,000 (10 to the power of 5) theoretical key differs. But in practice this number is reduced due to manufacturing variations, tolerances and other factors. This means there is the possibility, albeit slim, that two `keyed to differ` locks of the same design could have the same key pattern. To be absolutely certain locks have unique keys that aren’t duplicated, padlocks must be ‘guaranteed keyed to differ’. This requirement must be specified when the locks are ordered to enable the manufacturer to ensure supplied locks all use unique, specific keys. What does keyed alike mean? Keyed alike, also called ‘keyed to pass’, means one key can operate a group of keyed alike locks. All padlocks within the suite operate from a single key differ (key pattern). This means that any key from this collection will operate all of the locks in the suite. Many offices, businesses and residential homes used keyed alike systems as they reduce the numbers of keys that need to be managed. But concerns have been raised over the security implications, especially when keys are lost or misplaced. What does master keyed mean? A master keyed suite of padlocks uses a collection of ‘keyed to differ’ locks, each with their own unique keys and may also include one or more groups of `keyed alike` padlocks. A special ‘master key’ can be used on all of the padlocks in a master-keyed suite. The special ‘master key’ can only open the locks in this specific master-keyed suite and isn’t some kind of magical key that will open any lock. People often ask: How do master keys work? Cylinder locks are by far the most common lock design and the internal mechanism is what enables the master locking system. Pin and tumbler lock designs are the most common, using a collection of pins and a central, cylindrical plug. When the correct key is inserted into the lock cylinder the pins are pushed to establish alignment at what is called the ‘shear line’. If an incorrect key is inserted this alignment isn’t made and the lock will not operate. Master keyed locks include additional pins, called a master wafer or spacer. This is the special feature that enables master keyed locks to be opened using two distinctly different keys, the user key and the master key. Are master keyed padlocks as secure? The highest level of padlock security is provided by locks which are ‘guaranteed keyed to differ’ as this means just one key matches the padlock. If a padlock operates with both it`s own key and a master key there are fewer unique key combinations which means lower security. In practice, to allow for `master keying` a lock must offer a high number of key differs. For example, a padlock with possibly 500 key differs means the same key pattern will be repeated for every 500 manufactured locks. Making this lock part of a master keyed padlock suite halves this number to 250, lowering the level of security. But in practice most high quality padlocks available in both keyed-to-differ and master-keyed formats offer many tens or even hundreds of thousands of key differs. One of the most important security concerns associated with master keyed padlocks is the physical security of the master key - or keys. Obviously, if this important key fell into the wrong hands it would potentially allow access to many resources which highlights the need for rigorous physical key security. Can I have different padlocks in a master keyed set / suite? It is possible to have different padlock designs in a master keyed suite as long as they all use the same design of lock cylinder, from the same manufacturer. This is why, in our case study, our client was able to put together master keyed groups of padlocks of different designs (shutter-locks, long-shackle padlocks and marine padlocks) as they were all from the same manufacturer and all used the same lock cylinder. What are great grandmaster keys, grandmaster keys and master keys? The key hierarchy in a master-keyed system breaks down as follows: User keys are the normal lock keys that operate just one lock in a set or suite. Master keys are able to operate all locks in a set or suite of locks. Grand master keys refer to the next tier up in the master lock suite hierarchy. Some master key locking system designs (such as that described in the preceding case study) involve multiple master-keyed suites or sets of locks. Each of these might be managed by a supervisor or manager who therefore needs a master key to operate all of these locks. A grand master key (GMK) would enable the holder to operate all of the locks in a collection or group of master-keyed suites or sets of locks. Great grand master keys are used for yet another hierarchical level - above the grand master key level. It should be noted that not all padlock manufacturers offer systems that extend to the great grand master keyed level. Can I order more keys in the future? Yes. By maintaining a record of the locks and key patterns used in a master keyed suite replacement keys and locks can be readily ordered. What is a restricted padlock? A restricted padlock or key system means keys can only be duplicated by someone who is authorised to do so. Restricted padlocks might be partially restricted or fully restricted. Partially restricted padlocks come with special key-code cards that are used to obtain key copies. While it`s still possible for appropriately equipped locksmiths to copy keys without the card, most reputable locksmiths will require the card to be presented when key copies are requested. Fully restricted padlocks (patented padlocks) are also supplied with key-code cards. They take this form of key-copying protection security to another level by establishing legal patents, making it illegal to copy the keys or locks without having first verified ownership. Do insurance companies approve of master keyed padlock suites? Many insurance companies provide stipulations regarding the types of padlocks used to secure insured assets. Typically they might state that padlocks must have a minimum of 5 levers, must be of closed shackle design and should meet CEN grade 6 standards. (Read our guide to learn more about CEN ratings and standards for padlocks.) But most of the padlocks available today don’t have levers and while closed shackle padlock designs are inherently more secure, they vary enormously in quality and there are many excellent padlock designs that are highly secure yet don’t use closed shackles. When selecting padlocks to conform with insurance requirements it`s always a good idea to check specifics with the insurance provider. As a rule of thumb - always go for the highest quality padlocks that can be afforded and make certain they have been tested and certified to meet CEN and / or Sold Secure standards. If you have any questions about padlock security and whether master keyed suites are appropriate for your needs, remember that we are here to help. Give us a call on 01273 475500 and we’ll provide you with free, expert advice.

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