Dropsafe Drops Calculator

The calculator takes the user’s input of weight and height, and first works out the impact energy using basic physics: 

E=m×g×hE=m×g×h(mass × gravity × height)

• E (Energy): The impact force measured in Joules (J).
• m (Mass): The weight of the object in kilograms (kg).  
• g (Gravity): The acceleration due to gravity (9.81 m/s²).  
• h (Height): The distance the object falls in meters (m). 
  

Then, it applies a power-law model that links height thresholds to the object’s mass. That creates four severity bands – Slight, Minor, Major, Fatality – with cut-offs that shift with weight, so heavier objects reach high-severity bands from much lower heights than lighter tools. The calculator then outputs the corresponding severity level and description. 

The Dropsafe Drops Calculator is intended as a guide only. The purpose is to provide the user with a general idea of the potential severity of a dropped object. A detailed and specific risk assessment will always deliver a more accurate calculation of potential severity.  

The calculator assumes that full PPE (e.g., hard hat, safety boots, eye protection) is worn and that the object is blunt.  

The core DROPS Calculator model has remained consistent since its development by DROPS in the 1990s. This stability ensures continuity for the many organizations worldwide that rely on it as part of their HSE management systems, allowing for reliable long-term risk assessment practices.
The calculator model itself is industry-aligned and reflects decades of research consensus. By maintaining the original formula and severity classifications, we ensure that your risk assessments remain consistent with industry's best practice, while our platform improvements keep the tool relevant and user-friendly for modern workplaces.

No, the Dropsafe Drops Calculator estimates impact energy based solely on an object's mass and drop height. It does not account for material properties such as density, hardness, or brittleness. Consequently, a 2kg steel component and a 2kg wooden block dropped from the same height will generate the same calculated impact energy and severity rating. 

However, in a practical dropped object prevention scenario, material characteristics play a critical role in determining real-world consequences. While the calculated energy may be identical, the physical outcome of an impact can vary significantly: 

• Hard or Sharp Materials: Objects like steel tools or fasteners can concentrate force on a small surface area, potentially penetrating PPE or causing more severe trauma than blunt objects. 
• Brittle Materials: Items like concrete or certain plastics may shatter upon impact, creating secondary projectiles (shrapnel) that widen the hazard area. 

Therefore, while the calculator provides a vital baseline for energy and severity, it should be used in conjunction with professional engineering judgment. When assessing risks for hard, sharp, or brittle materials, best practice suggests escalating the hazard rating and implementing more robust prevention controls, such as Dropsafe Barriers or Nets to ensure comprehensive safety. 

The Dropsafe Drops Calculator is an industry-standard guide designed to estimate potential injury severity based on mass and drop height. It is a powerful tool for prioritizing dropped object prevention measures, but it is not a precise predictor of real-world outcomes due to several variable factors: 

• Object Characteristics: The model assumes a blunt object. It does not account for sharp edges (which increase penetration risk) or aerodynamic shapes that might alter fall trajectory. 
• Environmental Conditions: Factors like wind and deflection off structures are not calculated but can significantly influence impact energy. 
• Target Vulnerability: The calculator estimates risk to personnel wearing standard PPE (e.g., hard hats). It does not assess potential damage to critical asset infrastructure or machinery. 

Therefore, the calculator should be used as a baseline for risk assessment rather than a definitive forecast.

The “40 Joule rule” is a common industry guideline that says blunt impacts above roughly 40 J of energy can cause significant injury, even when someone is wearing normal PPE (hard hat, safety boots, etc.). Above about 100 J, the risk of severe or fatal injury rises sharply.

It’s best seen as a reference range, not a sharp legal cutoff: real-world outcomes still depend on the object’s shape, where it hits, and the person’s protection.

A 2 kg hammer dropped from around 5 metres (16 ft) is already in a range where a head impact could be fatal, even with a hard hat. From 10 metres and above, the same tool has a very high likelihood of causing death or life-changing injury.

Most industrial work at height (oil & gas, mining, wind, construction) takes place between 10–100+ metres, meaning ANY tool can become fatal if dropped. That’s why industry best practice emphasises engineered dropped-object controls (nets, barriers, tethering) alongside other measures, rather than relying on PPE alone.

No. A certified hard hat is essential, but it has limited capacity: it’s designed to manage lower-energy impacts and can turn a serious strike into a minor injury. 

For higher-energy drops, a hard hat cannot be relied on to prevent severe or fatal outcomes. That’s why engineering controls such as nets, barriers, and tool tethers are a crucial aspect of dropped object prevention, with PPE as the last line of defense.

Even small items can be deadly when dropped from typical work-at-height levels: a tool under 1 kg can cause catastrophic injury if it strikes someone’s head from a platform or structure. 

As weight increases, the height required for a potentially fatal impact drops quickly: a 5–10 kg tool or component can be life-threatening even from just a few metres. That’s why best practice in dropped-object prevention uses the hierarchy of control: elimination, substitution, engineering controls, administrative controls and PPE, rather than relying on PPE alone. 

Dropped object prevention follows the standard hierarchy of control: 

• Elimination: Remove the hazard entirely, for example by avoiding work at height or designing equipment so that loose items and temporary fixtures aren’t needed. 
• Substitution: Replace a higher-risk item or method with a safer one, such as using a lighter tool instead of a heavier one where practical. 
• Engineering controls: Physically prevent objects from falling or reaching people below, using solutions like nets, barriers, and tool tethers. 
• Administrative controls: Reduce exposure through procedures and planning, including exclusion zones, permit-to-work systems, inspections and clear communication. 
• Personal protective equipment (PPE): Hard hats, safety boots and other PPE form the last line of defence if all other measures fail, but should never be relied on alone.