4- tert -octylphenol (4- tert -OP) is an ecologically hazardous substance, and exposure to it in the environment has been consistently reported in the past. Despite the hazards and widespread exposure to 4- tert -OP, tools for scientific assessment of 4- tert -OP exposure risk level in humans are lacking. The main purpose of this study was to develop a physiologically-based-toxicokinetic (PBTK) model for 4- tert -OP and to perform quantitative risk assessment of 4- tert -OP in various population groups using the established model. Based on the results of toxicokinetic experiments on male rats, the PBTK model for 4- tert -OP was established and verified, and this was converted to a model for humans through interspecies extrapolation. Based on the previously reported no-observed-adverse-effect-levels for rats, it was possible to estimate the 4- tert -OP reference dose in humans through reverse dosimetry using the model. Biomonitoring data derived from various population groups were applied to the human PBTK model to calculate external exposures and margin of safety for 4- tert -OP for each population group. The PBTK model established in this study adequately explained the toxicokinetic experimental values at acceptable levels and was able to quantitatively predict the 4- tert -OP exposure level in the testes related to male reproductive toxicity. In addition, the degree of external exposure to 4- tert -OP could be scientifically estimated based on biomonitoring values derived from various biological matrices. The reference doses for systemic and reproductive toxicity caused by 4- tert -OP in male humans were calculated to be 0.16 and 1.12 mg/kg/day, respectively. The mean external exposure to 4- tert -OP in each population group estimated based on plasma and urine biomonitoring data was 0.04–66.24 mg/kg/day, showing very large exposure diversity between groups. Exposure risks to 4- tert -OP in populations ranged from safe to risky, suggesting the need for continued monitoring and risk management of 4- tert -OP worldwide. This study provides valuable scientific insight regarding the 4- tert -OP human risk assessment. [Display omitted] • A scientific human risk assessment of 4- tert -OP using PBTK modeling was performed. • PBTK model that can consider reproductive toxicity to men has been newly developed. • Large exposure variability of 4- tert -OP was confirmed between populations. • It was suggested that continuous management and monitoring of 4- tert -OP is necessary. [ABSTRACT FROM AUTHOR]