A Real Workplace Story

A technician repeatedly complained that his issued safety footwear was painful and uncomfortable during daily work. Because only limited sizes were available, he could not exchange the footwear for a better fit.

He later submitted an exceptional request to wear sports shoes instead of the issued model, but the request was declined. Over time, the discomfort became increasingly difficult to tolerate. Eventually, he decided to leave his job, with footwear-related pain being one of the main reasons behind his decision.

Stories like this raise an important question for organisations:

When does occupational footwear stop being a simple equipment issue and start becoming an operational, health, and retention problem?

Occupational footwear is often viewed primarily as a safety requirement designed to protect employees from external hazards. However, when safety footwear does not fit correctly, it may contribute to discomfort, reduced mobility, chronic pain, fatigue, absenteeism, and lower operational performance.

In sectors where personnel stand, walk, carry loads, or work long shifts — such as industry, logistics, healthcare, construction, security, police, or military services — footwear fit should not be treated solely as a comfort issue. It should also be considered part of a broader occupational health, procurement, and performance strategy.

The following five warning signs may indicate that your organisation is facing problems with ill-fitting footwear:

1. Frequent Heel Pain, Blisters, or Ankle Discomfort

One of the earliest warning signs is the repeated appearance of heel pain, friction blisters, Achilles discomfort, or ankle instability among employees. These problems may occur when safety footwear is too loose, too narrow, too rigid, or poorly aligned with the user’s foot shape and movement mechanics. Repeated heel slippage and instability may progressively affect walking patterns and lower-limb comfort. When these complaints become common within a team, they may indicate broader occupational footwear fit issues rather than isolated individual cases.

2. The Right Size Is Unavailable During Fit Testing

Another important warning sign appears during footwear allocation or fit testing sessions. Employees may wish to try several sizes during fit testing. However, due to limited stock availability — such as the absence of half sizes or width options — they may have to accept footwear that does not fit them properly. As a result, employees may be obliged to wear footwear that is only partially suitable for their feet and operational needs. Over time, repeated compromises in the fitting process may contribute to discomfort, dissatisfaction, and an increased risk of footwear-related problems within the organisation.

3. Increasing Rates of Chronic Foot and Lower-Limb Problems

In some occupational environments, employees may avoid reporting pain or discomfort during the early stages of injury due to working context.

As a result, problems are sometimes only reported once they become chronic and more difficult to manage. Examples may include:

• repeated ankle sprains progressing toward chronic ankle instability (CAI)

• persistent heel pain

• plantar fasciitis

• forefoot pain

• chronic lower-limb discomfort during long shifts

Research has shown that poorly fitted occupational footwear may contribute to foot pain and discomfort among workers wearing safety footwear for prolonged periods. When chronic complaints become increasingly common within an organisation, footwear fit should be considered as one possible contributing factor.

4. Increasing Footwear-Related Dissatisfaction and Staff Turnover

In some cases, employees become so dissatisfied with issued footwear that they:

• avoid wearing it whenever possible

• purchase alternative footwear at their own expense

• repeatedly complain about discomfort

• request exceptional accommodations

• or eventually leave the organisation

Although staff turnover is influenced by many factors, recurring complaints related to occupational footwear may contribute to frustration, reduced morale, and lower job satisfaction.

5. Footwear Problems Become “Normalised”

In many organisations, foot pain and discomfort are gradually accepted as “part of the job.” However, recurring discomfort should not automatically be considered normal. Early signs such as friction, instability, numbness, or excessive fatigue may indicate underlying footwear fit issues that deserve attention before they evolve into more serious long-term problems. A proactive approach to footwear fit may help organisations improve comfort, reduce preventable complaints, and strengthen overall occupational wellbeing.

Why The Warning Signs of Ill-fitting Footwear Matter for Organisations

Ill-fitting occupational footwear may affect more than individual comfort.

Potential consequences may include:

• increased absenteeism

• reduced operational performance

• lower employee satisfaction

• increased chronic injury risks

• footwear non-compliance

• higher long-term health-related costs

• retention difficulties in physically demanding professions

For organisations operating in demanding occupational environments, footwear fit should be viewed as part of a broader prevention and performance strategy rather than simply an equipment purchasing decision.

Conclusion

Safety footwear should not only protect workers from external hazards — it should also fit correctly and support employees throughout daily operational demands.

The warning signs discussed above may help organisations identify potential occupational footwear fit problems before they evolve into larger health, operational, or retention issues.

At Oliverland Consulting, we help organisations better understand occupational footwear fit through:

• fit education

• procurement diagnostics

• fitting process analysis

• structured occupational footwear fit approaches

Our objective is to help organisations reduce avoidable footwear-related problems while improving operational comfort, consistency, and long-term organisational performance. If your organisation experiences recurring footwear-related complaints or fitting challenges, a free 30-minute consultation is available to discuss your current situation and possible improvement strategies.