Commercial Construction Site Setup Checklist: Essential Supplies & Safety Equipment NSW

I’ve watched sites get shut down on day one because someone forgot emergency exits were required. Seen projects delayed two weeks waiting for safety barriers that should have been ordered with the site fencing. Had inspectors red-tag work sites over missing PPE that cost $300 to fix but caused $15,000 in delays.

Site setup isn’t glamorous, but get it wrong and your commercial project is dead before you pour the first footing.

Here’s the actual checklist that gets sites through inspection and keeps SafeWork NSW happy, based on managing commercial projects across Sydney and NSW.

Pre-Start Legal Requirements (NSW)

Before anyone swings a hammer, you need these boxes ticked:

Site Registration and Permits

Required for commercial projects:

Development approval (obviously)
Construction certificate
Principal contractor appointment (under WHS Act)
Public risk insurance ($20M minimum typical)
Workers compensation insurance

SafeWork NSW notification:

Projects over $250,000 require notification
High-risk construction work requires specific notification
Demolition requires separate notification

Council requirements:

Road occupancy permit (if applicable)
Hoarding approval
Tree protection approval (if applicable)
Vehicle crossing permit

Failure story: Watched a $3M fitout project get stopped day one because principal contractor notification wasn’t submitted to SafeWork NSW. One week delay while paperwork processed.

Site Signage (Mandatory)

Main entry sign must display:

Principal contractor details
Project value
Safety contact numbers
Emergency contact information

Minimum sign size: 900mm x 600mm, visible from street

Additional signage required:

“Construction site – authorized access only”
Emergency evacuation plan
Emergency assembly point
First aid location

Fines: Up to $6,000 for inadequate site signage

Safety Barriers and Perimeter Protection

Getting the site boundary right is critical:

Temporary Fencing

Requirement: Minimum 1.8m height temporary fencing for all commercial sites

Quantity calculation: Measure site perimeter, add 20% for corners and gates

Panel types:

Standard chain mesh panels: $20-25 per panel (hire)
Solid hoarding: $40-60 per panel
Acoustic barriers: $80-120 per panel (required near residential)

Typical commercial site: 50m x 30m perimeter = 160m fencing = ~55 panels

Gates required:

Pedestrian gate: Minimum 1 per site
Vehicle gate: Minimum 2.4m wide (3.6m better for trucks)

Real requirement: Gates must be lockable, inspectors check this

Installation tips:

Fence bases must be stable (sandbags or concrete weights)
No gaps under fencing (debris containment)
Regular inspection for damage or movement

Edge Protection (Height Work)

Required for: Any work over 2 meters (not 3 meters – that’s outdated)

Standard systems:

Top rail: 1m above working surface
Mid-rail: 500mm above working surface
Toe board: 150mm minimum height

Alternative: Catch nets or safety mesh (but permanent edge protection preferred)

Cost reality: Edge protection for typical two-story commercial: $8,000-12,000 for compliant system

Traffic Management

When required: Any work affecting public areas, roads, or footpaths

Minimum requirements:

Traffic control plan approved by council
Appropriate signage (witches hats, bunting, warning signs)
Qualified traffic controllers if managing vehicle flow

Equipment needed:

Witches hats (900mm height minimum): 20-30 typical
Bunting: High-visibility, reflective
Warning signs: Road work ahead, detours, etc.

Sydney CBD specifics: Council requirements are stricter, inspection more frequent

Browse our site supply catalogue for temporary fencing, barriers, and traffic management equipment.

Site Amenities (Legal Requirements)

These aren’t optional – they’re WorkCover mandated:

Toilets

Requirement: 1 toilet per 20 workers

Commercial site with 40 workers: Minimum 2 toilets required

Standards: Must be clean, stocked, functional, accessible

Type: Portable toilets acceptable, must be serviced weekly minimum

Common violation: Running out of toilet paper. Seriously. Inspectors check this.

Cost: $45-60 per week per unit including service

Drinking Water

Requirement: Clean, cool drinking water readily available

NSW summer reality: Not just available – COOL water required

Options:

Bottled water stations (expensive, generates waste)
Plumbed water coolers (better for extended projects)
Frequent delivery of iced water

Minimum: One water source per 30 workers

Washing Facilities

Requirement: Hand washing with soap and clean water

Setup options:

Portable hand wash stations
Connected to site water supply
Soap dispensers (must be stocked)

Critical for: Sites handling chemicals, concrete, or hazardous materials

Rest Areas

Requirement: Shaded rest area with seating for all workers during breaks

Minimum spec:

Protection from weather
Seating for all workers
Located away from active work areas

Reality: Demountable shed or large site tent typical

Size guide: Allow 1m² per worker minimum

Personal Protective Equipment (Site-Wide)

Every person on site needs minimum PPE:

Hard Hats

Requirement: AS/NZS 1801 certified, in good condition

Type needed: Type 1 minimum (Type 2 better for demolition/high-rise)

Cost per worker: $40-80 for quality helmet

Check for:

Manufacturing date (replace after 5 years)
Cracks or damage
Functioning chin strap (required for height work)

Safety Boots

Requirement: AS/NZS 2210.3, minimum 130J steel toe cap

Cost per worker: $180-220 for quality boots

Check for:

Undamaged steel toe cap
Sole not worn through
Proper ankle support

High-Visibility Clothing

Requirement: AS/NZS 1906.4:2010 Class D minimum (Class D/N for night work)

Must have:

Fluorescent background (orange, yellow, or red)
Reflective strips in correct configuration (50mm minimum)
Good condition (faded = non-compliant)

Cost per worker: $25-40 per shirt/vest

Sydney summer tip: Moisture-wicking fabric worth the upgrade

Safety Glasses

Requirement: AS/NZS 1337.1 medium impact rated

Must have:

Side shields
Clear or tinted (site-specific)
Anti-fog coating (Sydney humidity)

Cost per worker: $15-25

Hearing Protection

Required when: Noise exceeds 85dB (most commercial sites)

Options:

Disposable earplugs: $0.50-1 per pair
Reusable earplugs: $5-10
Earmuffs: $20-40

Reality: Earmuffs better because compliance is visible

Work Gloves

Requirement: Task-appropriate gloves

Stock multiple types:

General riggers: $8-12 per pair
Cut-resistant: $15-25 per pair
Chemical-resistant: $10-20 per pair

Budget for: Workers need 2-3 pairs per week typically

First Aid and Emergency Equipment

Non-negotiable requirements:

First Aid Kits

Requirement based on workers:

Under 10 workers: Basic kit
10-50 workers: Workplace kit
Over 50: Workplace kit plus trauma kit

Must contain:

First aid manual
Bandages, dressings, tape
Eye wash station
Burn treatments
Resuscitation face shield
Scissors, tweezers
Gloves
Record book

Location: Clearly marked, easily accessible, protected from weather

Cost: $150-400 depending on size

First Aid Officers

Requirement:

Sites with 10+ workers need trained first aider
Certificate must be current (3-year validity)
More than one required if shifts mean first aider not always present

Training cost: $150-200 per person

Record keeping: Maintain register of first aid incidents

Fire Extinguishers

Requirement: Type ABE (dry powder) for construction sites

Placement:

At least one per floor/level
Within 30m travel distance of any point
Near site offices/amenities

Service requirement: Annual inspection and tagging

Cost: $80-120 per unit

Spill Kits

Required for: Sites using chemicals, oils, paints

Must contain:

Absorbent materials
PPE for cleanup
Disposal bags
Instructions

Location: Near chemical storage, easily accessible

Tool and Equipment Setup

Getting your gear organized from day one:

Secure Storage

Site sheds/containers:

Weather-proof tool storage
Lockable (insurance requirement)
Organized to prevent tool loss

Typical setup: 20ft container for tools, 20ft for materials

Cost: $150-250 per week rental

Power and Lighting

Temporary power:

Main distribution board
RCD protection (30mA)
Weatherproof outlets
Extension leads (industrial-rated)

Lighting:

Site lighting for early/late work
Emergency lighting near exits
Adequate task lighting for detailed work

Safety requirement: All electrical work by licensed electrician, tagged and tested

Lifting Equipment

If using cranes/hoists:

Current inspection certificates
Rated capacity clearly marked
Trained operators only
Exclusion zones marked

Material Storage and Handling

Proper storage prevents waste and safety issues:

Storage Areas

Designate zones for:

Timber/plywood (covered, dry)
Steel (supported properly, organized by size)
Fasteners and fixtures (weatherproof, organized)
Chemicals (bunded, ventilated, secure)
Waste (separate bins for different materials)

Chemical Storage

Requirements:

Bunded area (containment for spills)
Ventilated
Locked
Signage (dangerous goods labels)
SDS (Safety Data Sheets) accessible

Common chemicals:

Adhesives
Sealants
Paints
Concrete additives

Waste Management

Bin requirements:

General waste
Recycling (cardboard, plastic, metal)
Concrete/masonry
Timber

Size for commercial site: 6m³ or 8m³ skip bins typical

Service frequency: Weekly minimum, daily for active demolition

Site-Specific Fasteners and Fixings

Stock these from day one:

Temporary Fixings

What you’ll need immediately:

Temporary barrier fixings
Hoarding brackets and fasteners
Protection board mounting
Edge protection anchors

Quantity: Over-order by 30% – temporary works always need more than planned

General Construction Fasteners

Stock in bulk:

Self-drilling screws (various sizes)
Timber screws and nails
Masonry anchors
Structural bolts (if doing steel work)

Organization tip: Mobile gang boxes for different fastener types

Browse our complete fastener range for bulk site supply ordering.

Safety Management Systems

Documentation that must be on site:

SWMS (Safe Work Method Statements)

Required for: All high-risk construction work

Must cover:

Task description
Hazard identification
Risk controls
PPE requirements
Emergency procedures

Who signs: All workers performing the task

Inspection check: Inspectors will ask to see SWMS for current work

Site Induction Records

Requirement: All workers must complete site induction before starting

Must cover:

Site-specific hazards
Emergency procedures
PPE requirements
Site rules

Record keeping: Maintain register of inducted workers

Toolbox Talks

Frequency: Weekly minimum (daily for high-risk work)

Documentation: Sign-in sheet, topics covered, any issues raised

Topics rotate: Safety, quality, environmental, productivity

NSW-Specific Compliance

Additional requirements for NSW sites:

SafeWork NSW Inspections

Expect inspections:

Random at any time
Complaint-triggered
Post-incident

What they check:

PPE compliance
Edge protection
Electrical safety
SWMS documentation
Worker licenses/qualifications

Fines: $6,000-60,000 for serious violations

Sydney Council Requirements

Council inspectors check:

Hoarding and fencing
Footpath protection
Traffic management
Noise compliance
Work hours (typically 7am-5pm weekdays, 8am-1pm Saturdays)

Tip: Know your council’s specific requirements – they vary significantly

Opening Day Checklist

Before first workers arrive:

☐ Perimeter fencing complete and secure
☐ Site signage installed (main sign + safety signs)
☐ Toilets delivered and positioned
☐ Drinking water available
☐ Rest area set up with seating
☐ First aid kit accessible and stocked
☐ Fire extinguishers positioned and tagged
☐ Tool storage secure and organized
☐ Temporary power connected and tested
☐ Site access clear and safe
☐ Emergency evacuation plan posted
☐ PPE stock available for all workers
☐ Site induction materials ready
☐ SWMS prepared for initial works
☐ All permits and approvals obtained

Cost Reality: Budget for Site Setup

Typical commercial project (40 workers, 12-month duration):

One-time setup costs:

Fencing and hoarding: $8,000-15,000
Site sheds/containers: $5,000-8,000
Safety equipment (initial stock): $6,000-10,000
Signage: $1,000-2,000
First aid and fire safety: $1,500-2,500
Total one-time: $21,500-37,500

Ongoing monthly costs:

Toilet service: $800-1,200
Water delivery: $200-400
PPE replacement: $800-1,200
Waste removal: $1,200-2,000
Total monthly: $3,000-4,800

Don’t cheap out: Cutting corners on site setup costs way more when SafeWork shows up.

Common Setup Mistakes

Failures I’ve seen repeatedly:

Mistake 1: Inadequate toilet facilities
Result: Work stop order, $5,000 fine, 3-day delay

Mistake 2: No drinking water in summer
Result: Heat-related incident, SafeWork investigation, possible prosecution

Mistake 3: Missing site signage
Result: $6,000 fine, compliance order

Mistake 4: Insufficient PPE stock
Result: Workers sent home, day lost, productivity impact

Mistake 5: Poor material storage
Result: Damaged materials, waste, weather delays

Getting Expert Help

Complex commercial sites need proper planning:

Professional services:

Traffic management companies
Safety consultants
Site setup specialists

When to engage experts:

First major commercial project
Complex CBD sites
High-risk work environments

The Bottom Line

Proper site setup for NSW commercial construction requires:

Complete safety compliance (barriers, PPE, amenities)
Adequate first aid and emergency equipment
Proper material storage and organization
Full documentation and management systems
Council and SafeWork NSW compliance

Budget 1-2% of project value for site setup and safety. Trying to save money here is penny-wise, pound-foolish.

Get setup right in week one, and your project runs smoothly. Get it wrong, and you’re dealing with inspectors, delays, and fines instead of building.

Need site supply for your NSW commercial project? TOPFIX supplies complete site setup requirements including safety equipment, temporary fencing, fasteners and consumables. Visit our site supply catalogue or call 1300 867 349 for trade pricing and project support.

Site Supply Products Available:

Temporary Fencing and Barriers
Traffic Management Equipment
PPE and Safety Gear (AS/NZS Certified)
First Aid Kits and Fire Safety
Site Fasteners and Fixings
Material Storage Solutions
Bulk Trade Pricing
Delivery Across Sydney and NSW

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