The hidden dangers of worn-out safety boots (and when to replace them)

Worn out safety boots don’t just look unsightly, they’re also likely to be uncomfortable to wear, and could even be dangerous to your employees. Here’s why you should be inspecting your safety footwear regularly for signs of damage or wear and tear – and replacing it at the first sign of a problem.

Safety boots for the logistics industry

Safety boots are a ‘must’ for people working in logistics, helping to keep them comfortable and protected from hazards in the workplace all year round.

When they’re of good quality to begin with, and well-maintained throughout their lifespan, a pair of safety boots might be expected to last 18 months or more in constant use.

How long should safety boots last? Find out everything you need to know in our blog on choosing the right safety footwear for your team.

But, once worn out or damaged, old safety boots must be replaced straight away, as the risk of accidents and injuries increases with every day they are worn thereafter.

When safety boots turn dangerous

Worn out or damaged safety boots are unlikely to protect the wearer’s feet against workplace hazards, and may even cause accidents and injuries of their own.

For example:

• Bent or dislodged toe caps and torn uppers can increase the risk of crush and cut injuries respectively in workplaces where those hazards are present.
• Split or worn-down soles can cause people to trip or slip on hard floors.
• Worn midsoles can lead to poor foot positioning within the boot, causing increased strain on the muscles and ligaments in the lower leg and foot when walking around the factory or warehouse floor. As well as increasing the risk of injury, over time the cumulative effect could contribute to a long-term persistent musculoskeletal condition.
• Worn down linings and insoles can cause the feet to sweat, making boots uncomfortable during wear and increasing the risk of skin irritation.

To avoid these risks and more, it’s important to regularly inspect all safety footwear and to replace it at the first sign of an issue.

Safety boot inspection: What to look out for

So, how do you know when your safety boots need replacing? Some signs to look out for include:

They are damaged
The number one reason to replace your safety boots would be if they become damaged for any reason; for example if anything heavy impacts the protective toe cap, if the boot comes into contact with a hazardous chemical, or if a sharp object penetrates the protective upper or sole. It is highly unlikely in these instances that, once it has protected the wearer’s feet once, a protective feature will retain the same level of performance should the hazard be encountered in future.

The tread is worn
The tread on the sole of safety boots will wear down with use and, after a time, this can vastly reduce slip resistance. Look out, too, for wear on the sides of the boot, which may reduce the support it can provide to the wearer’s ankle.

There are visible signs of wear and tear
Look closely at the uppers – are they starting to break down? Is all the stitching intact around the shoe, or is it starting to come apart in places? Are the soles starting to split and come away?

They just aren’t as comfortable anymore
When it comes to safety boots, losing comfort over time is a classic sign that something is wrong. This includes a sudden onset of causing the feet to sweat, which could be due to a worn insole or lining breakdown.

They have reached the end of their shelf life
All safety footwear should come with a manufacturer’s warranty guaranteeing it for a certain amount of time. With employers responsible for removing PPE that has reached its shelf life, this date should be logged and the footwear replaced once it reaches that date, even if it appears to be in good condition.

In all of the above cases, the safety boots are no longer fit for purpose and should be replaced.

Maximising safety boot lifespan

To get the maximum lifespan from your safety boots, they should be worn with respect and stored with care.

Start by choosing a quality product. Discover the best safety boots on the market today and read our guide to choosing what’s right for your business.

Once you’ve chosen your safety boots, they should last at least as long as the manufacturer’s warranty, providing you take good care of them by keeping them clean, allowing them to dry naturally before they are put away, and applying polish or wax to any leather uppers.

Having problems with your safety boots? If your safety footwear isn’t lasting as long as it should, give our team a call – we guarantee we can help you solve the issue!