Calculator inputs
Example data table
| Rated load (kg) | Usable factor | Avg weight (kg) | Area (m²) | Density (persons/m²) | Combined capacity (persons) |
|---|---|---|---|---|---|
| 800 | 0.90 | 75 | 1.8 | 3.0 | 5 |
| 1000 | 0.85 | 80 | 2.2 | 3.5 | 7 |
| 1200 | 0.90 | 75 | 2.6 | 3.0 | 7 |
| 1600 | 0.90 | 85 | 3.0 | 3.0 | 10 |
| 2000 | 0.95 | 75 | 3.6 | 3.5 | 13 |
Formula used
How to use this calculator
- Enter the equipment rated load and choose a usable factor.
- Set an average passenger weight suitable for your crew.
- Add usable floor area after accounting for obstructions.
- Choose density or space per person based on comfort and PPE.
- Use the combined method, then apply site rules and signage.
Article
Design intent and compliance context
Passenger limits are a control measure that supports safe movement of crews in hoists, site shuttles, and temporary lifts. A practical capacity should respect equipment ratings, operational margins, and the working conditions created by PPE, tools, and weather. Use the output to support signage, briefings, and daily checks alongside manufacturer guidance and local rules.
Key inputs that drive capacity
Start with rated load and apply a usable factor to reserve capacity for tools, radios, and incidental loads. The weight-based limit is the usable load divided by an average passenger weight, rounded down. Adjust the average weight upward for winter clothing, harnesses, or material handling. Small changes in these values can move the safe limit by multiple people.
Area allowance and crew movement
Area-based capacity reduces crowding risk and improves egress. A density approach (persons per square metre) works well for quick planning, while space per person supports stricter comfort or distancing targets. Higher PPE bulk, stretcher access, or uneven flooring should be reflected by lowering density or increasing space per person.
Interpreting governing capacity
Combined capacity uses the smaller of weight and area results, creating a conservative limit. When the two values differ significantly, review whether the area estimate is realistic or whether the usable factor should be more conservative. Track remaining usable load to confirm that the chosen passenger count stays below the reduced load limit.
Worked example for daily briefing
Example data: rated load 1000 kg, usable factor 0.90, average weight 75 kg, usable area 2.2 m², density 3.0 persons/m². Usable load = 900 kg, capacity by weight = ⌊900/75⌋ = 12 persons, capacity by area = ⌊2.2×3.0⌋ = 6 persons. Governing capacity = 6 persons, load used = 450 kg, remaining usable load = 450 kg.
FAQs
1) Which method should I use for planning?
Use the combined method for conservative planning because it respects both load and crowding constraints. Switch to weight-only or area-only only when a qualified procedure explicitly requires it.
2) What does the usable load factor represent?
It reduces the rated load to allow for tools, PPE, uneven distribution, and operational margin. A lower factor is more conservative and typically produces a smaller passenger limit.
3) How do I choose average passenger weight?
Use a conservative site average that reflects clothing, harnesses, and carried items. If uncertain, select a higher value to avoid overestimating capacity.
4) When should I use density versus space per person?
Use density for quick occupancy planning and space per person when comfort, distancing, or bulky PPE matters. Space per person is often easier to justify during audits.
5) Why is my area capacity much lower than weight capacity?
Limited usable floor area, obstructions, or conservative spacing assumptions can restrict occupancy before load does. Recheck the usable area and confirm the chosen density or space per person.
6) Does the result replace manufacturer instructions?
No. Treat the result as a planning aid. Always follow manufacturer labeling, inspection requirements, and local safety regulations, and post the stricter limit if values conflict.
7) How should I document capacity for supervisors?
Export the CSV or PDF, attach it to the lift or shuttle checklist, and note the assumptions used. Update the inputs whenever crew weights, PPE, or site conditions change.