How To Make Safety Shoes Comfortable

Safety shoes are designed for protection - but it’s equally important that they are comfortable to wear. It’s up to the buyer to purchase good-quality, comfortable shoes - and the good news is that this doesn’t have to cost the earth.

In this article, we will explore the problems caused by badly-fitting footwear, and explain how to make safety shoes comfortable.

What is the problem with bad safety shoes?

Poorly-fitting shoes can cause problems like rubbing, crushed toes, heel lift, and pressure points. Not only is this painful for the wearer, but it can also reduce productivity and staff satisfaction.

Foot pain can make people less focused, less productive, and less willing to wear their PPE properly. If footwear is uncomfortable, workers will notice it all day.

Complaints about safety boots and shoes are often treated as “moaning”, but they should be taken seriously - and they often point to a poor buying decision.

The company buyer has a direct influence on whether safety footwear is tolerated, liked, or avoided by the workers who need to wear it.

The right shoe for the right role

It’s important that safety shoes and boots offer the appropriate protection, but sometimes safety features are unnecessary for a particular role or task. Over-specifying footwear can make it heavier, hotter, and less comfortable.

Safety trainers typically suit warehouse, logistics, light industrial and indoor environments, while safety boots may be better for construction, groundworks, utilities, and outdoor work.

Waterproof boots are also ideal for wearing outdoors, but they may feel too warm if worn indoors. Dealer-style boots can be convenient but they may not suit every foot shape.

Key considerations

• Match footwear to the task, not just the safety rating.

• Ask what protection the team actually needs (ankle support, water resistance, metatarsal protection, anti-static properties, slip resistance, penetration resistance, heat resistance)

• Avoid supplying “one boot for all” unless the working environment is genuinely the same for everyone.  

Size isn’t everything

It’s worth remembering that different brands - or even different styles from the same brand - can fit differently, and someone may need a different size for their safety footwear than they do for their everyday shoes.

But it’s not just about getting the right size of shoe. Width matters as much as length, and some workers may need wide-fit options. And protective toe caps can make a shoe feel smaller if the fit is wrong.

Half sizes or alternative styles can make a big difference. A business may prefer every team member to have matching shoes, but may have to accept that this is less important than getting the right fit.

Key considerations

• Don’t assume that everyone will be comfortable in the same shoe or boot

• Offer a choice of styles where possible

• Keep a small range of different sizes or a sample set on site so that workers can try the footwear

• Create a simple footwear request process for new starters or for people to order replacement shoes when needed.

What about insoles and socks?

Well-fitting shoes and boots will provide comfort, but accessories can also play their part. Insoles can improve cushioning and arch support - consider buying shoes with several insole options so that you can fine-tune the fit.

While insoles can enhance the fit of a shoe that’s slightly too large or wide, it’s always better to get a good fit in the first place.

Good work socks reduce rubbing and help manage moisture, whereas thin “fashion socks” can make safety footwear feel less comfortable.

Key considerations

• Consider offering proper work socks as part of the PPE package

• Keep replacement insoles in stock for common footwear styles

• Replace insoles before the footwear itself wears out, as insoles can’t compensate for a failing shoe.

• The small add-on cost of accessories can dramatically improve comfort.

How to handle problems

Be aware that some footwear needs time to bed in, and some leather boots may soften slightly after a few wears. However, new footwear should not cause significant pain, blisters, or numbness.

Persistent discomfort usually means the wrong fit, wrong style, or poor-quality footwear. Staff should be encouraged to report issues early, rather than trying to push through.

Key considerations

• Set up a clear process for dealing with footwear complaints

• Identify any repeat issues with certain styles or brands

• Use wearer feedback to improve future buying decisions.

Extra tips for comfortable safety shoes

Here are a few more things you can do to ensure everyone’s shoes fit well.

Consult the experts

If you’re buying multiple pairs of safety shoes for a medium to large workforce, it’s a good idea to host a fitting day. This is when a representative from a footwear provider comes to visit your company. 

They’ll measure everyone’s feet to achieve the right fit, and advise on which shoes or boots are best for various requirements. Sixton Peak is one of the brands that offers this service.

Alternatively, get in touch with manufacturers or suppliers and ask for advice or further information about their products.

Buy for long-term value

Don’t be tempted to buy cheap safety footwear. What looks like the cheapest pair of shoes on paper may not work out to be the best value for money over its lifetime.

This is because low-quality footwear can wear out faster. It may rub, split, or lose its shape, and offer poor cushioning. Uncomfortable boots can also lead to more returns and replacements, which comes with its own cost.

However, good footwear doesn’t necessarily come with a premium price tag - there are some solid mid-range options that offer the right level of comfort and protection.

Take care with insoles

It’s vital that any insoles or other accessories are compatible with the shoe they’re being used in. As well as potentially reducing comfort, non-approved insoles could even mean the safety shoe is no longer compliant with the required safety standard.

This can affect the company’s liability insurance and workers’ personal injury claims. Always check the footwear’s technical datasheet to see if the manufacturer sells certified replacement insoles, or approves any alternative insoles for use with its shoes.

The takeaway

Uncomfortable safety footwear is bad news for everyone - it leads to discomfort, avoidance of wearing PPE, and a poor return on investment. Ensuring a good fit is crucial - and you’ll get a head start if you buy quality work boots and shoes from a reputable company.

You’ll find a huge selection of safety footwear in our store, or you can contact our friendly sales team for more advice.