Foot protection fit

Responding is Kate Harrison, Ph.D., manager of biomechanics research, BOA Technology, Denver.

The primary purpose of safety footwear is to protect workers from acute hazards on the worksite, including puncture, impact, electrical shock, etc. In most regions, safety standards are strictly set and tested for any footwear on the market, giving workers and employers confidence in the reduced risk of immediate injury.

Yet, an important consideration remains: How does safety footwear impact worker health and injury long term?

For industrial athletes who engage in physical work for more than 40 hours a week, rates of musculoskeletal discomfort, pain and injury are high, a recent study shows. Researchers and manufacturers must consider how we can better equip workers to stay healthy and productive throughout their careers.

Footwear fit is a significant challenge for industrial workers. Researchers in Australia recently conducted extensive studies on boot fit – specifically in the coal mining industry – and documented resulting issues such as foot pain, musculoskeletal injury and altered biomechanics. They found that standard work boots often fail to match the natural shape of workers’ feet. Most workers wore boots that were too long, likely compensating for insufficient width, which can contribute to foot pain and movement inefficiencies. To address these issues, the researchers recommended that manufacturers refine the shape of the last – the mold that determines a boot’s structure – to better align with the typical worker’s foot dimensions.

Beyond the impact of lasts on fit, the method used to secure the boot also plays a crucial role in footwear function. For example, switching from a slip-on gumboot to a lace-up boot improves perception of fit and support. However, musculoskeletal pain may persist even with laces, a recent study published in the journal Applied Ergonomics shows. More recent advancements show that switching from laces to boots that wrap around the foot can further improve stability.

Ensuring a close fit provides stability to the foot and ankle, as well as more proximal joints, which reduces risk factors associated with knee injury and osteoarthritis, a team of Australian researchers has found. Today, many workwear retailers offer fitting via online photo tools or in-person foot scanning with expert guidance to ensure the best possible fit for each worker.

The materials used in safety footwear play a significant role in balancing protection and long-term health. Stiff materials are commonly used to resist puncture and impact and are often assumed to provide support. However, research shows that rigid materials actually increase joint loading. By restricting foot and ankle movement, workers are forced to rely more on their knees, hips and back, increasing the risk of overuse injuries. Not only can pain become an issue, but it also impacts performance, reducing the amount workers can lift. Further, restricted motion at the ankle increases the risk of tripping, another study found.

Recognizing these challenges, the footwear industry has increasingly focused on developing innovative materials. For example, flexible, lightweight materials can provide the same support as traditional rigid structures while improving efficiency, Chinese researchers have discovered. Further, brands are also introducing composite materials to provide effective impact protection at a fraction of the weight.

Historically, safety footwear prioritized protection against immediate hazards, often at the expense of long-term health. However, advancements in design, fit and materials are shifting this balance. Given the data demonstrating the potential for reduced overload and improved worker performance, employees and organizations alike should consider investing in modern footwear technology and solutions for long-term health and productivity.

Editor's note: This article represents the independent views of the author and should not be considered a National Safety Council endorsement.