Example data table
| Scenario | Inputs | Selected hazards | Typical output highlights |
|---|---|---|---|
| Concrete slab with cutting |
Crew: 12 Days: 10 Shifts/day: 1 Dust: Medium Noise: Medium Spare: 10% |
Cutting, Grinding, Silica (if present) |
Reusable: hard hats, vests, glasses, boots, goggles. Disposable: gloves (~120+), hearing protection (~60+), dust masks (~120+). |
Formula used
Reusable item base quantity: Base = Crew
Disposable item base quantity: Base = Crew × Days × Shifts × Use Rate
2) Spare buffer
Spare = ceil(Base × Spare%)
Total = Base + Spare
3) Trigger rules (examples)
- Fall protection triggers when height ≥ 2 m or fall hazard selected.
- High dust or silica triggers particulate respirators per shift.
- High chemical exposure triggers suits and chemical gloves.
- Confined space triggers gas detection and rescue planning.
How to use this calculator
- Enter crew size, shifts, and project duration.
- Set dust, noise, and chemical exposure levels.
- Confirm your baseline PPE requirements for all workers.
- Select hazards that match the planned tasks and environment.
- Adjust consumable usage rates to match your policy.
- Click Calculate to view the PPE list and quantities.
- Download CSV or PDF for planning, audits, and toolbox talks.
1) Why a PPE requirement plan matters
A PPE plan turns hazards into measurable inventory and clear responsibilities. On busy sites, the gap is rarely knowledge; it is availability, fit, and timing. This tool converts scope and hazards into quantities.
2) Baseline PPE versus task-driven PPE
Many projects enforce a “site minimum” set: hard hats, high-visibility wear, eye protection, and safety boots. Task-driven PPE is added when specific hazards are present, such as welding, hot work, electrical exposure, silica dust, or confined-space entry. Separating these two layers reduces over-ordering and improves compliance.
3) Practical quantity math for procurement
Reusable items generally scale with headcount, while disposables scale with time and shift patterns. A common planning approach is Base = Crew × Days × Shifts × Use Rate for consumables. Add a spare buffer (often 5–15%) to cover loss, damage, contamination, and late joiners.
4) Height and fall-risk triggers
Many site rules require fall protection when work height reaches about 2 meters or when a fall hazard exists. Planning one harness kit and compatible lanyard per exposed worker avoids schedule delays and unsafe shortcuts. Track inspection cycles and remove equipment from service after any shock load.
5) Dust, silica, and respiratory selection
Dust exposure varies by activity, ventilation, and controls. For medium dust, one disposable mask per worker per day is a common baseline. For high dust or silica-related tasks, per-shift respirators or reusable respirators with consumable filters are often planned. Fit and seal checks are as important as stock levels.
6) Noise and hearing protection planning
Grinding, cutting, and heavy equipment can push exposure into ranges where hearing protection is needed. A practical stocking method is one pair per worker per shift for high-noise tasks and half that rate for intermittent noise. Pair procurement with toolbox talk reminders and correct insertion training.
7) Chemical exposure and splash control
Chemical risk depends on product, concentration, and work method. High exposure planning commonly includes splash goggles, chemical-resistant gloves, and disposable suits for messy tasks. Keep replacement guidance simple: change after contamination, visible degradation, or per task duration defined by your policy.
8) Using outputs for audits and daily control
The exported CSV supports procurement tracking, while the PDF report helps pre-task briefings and inspections. Compare issued totals against planned totals to detect shortages early. When conditions change—new subcontractors, weather, or added high-risk tasks—recalculate and reissue the updated checklist for consistent site control.
1) Does this replace a formal risk assessment?
No. It supports planning by estimating quantities from selected hazards. Always confirm requirements with your
site safety plan, permits, and competent-person judgments before issuing PPE.
2) How should I choose the spare buffer percentage?
Use 5–10% for stable crews and controlled storage. Use 10–15% for multi-trade sites, high turnover, or harsh
environments where damage and loss are more likely.
3) What does “use rate” mean for disposable items?
Use rate is the typical number consumed per worker per day or per shift. Examples include glove pairs per day,
masks per day, or earplug pairs per shift, based on your policy and task intensity.
4) Why are some items marked reusable?
Reusable items are issued and maintained, such as hard hats, harnesses, face shields, and detectors. They need
inspections and replacement after damage, expiry, or specific events like a fall arrest activation.
5) When should I select the confined space option?
Select it when entry permits or atmospheric hazards are possible. The calculator adds monitoring and rescue
planning items. Confirm exact equipment, calibration, and staffing requirements with your confined-space program.
6) Can I use this for subcontractors and visitors?
Yes. Include them in crew size or increase the spare buffer. Many sites keep extra baseline PPE for visitors,
but specialized PPE should be matched to the tasks and training of those entering the work zone.
7) Why do my totals change when I adjust shifts?
Consumables scale with exposure time. If a respirator or hearing protection is used per shift, adding shifts
increases consumption and replacement frequency, so the calculator increases quantities accordingly.