The evolution of safety footwear for the e-commerce era

The past several years have seen the e-commerce industry soar. In 2020 alone, e-commerce sales increased by over 33%, a staggering indication that the COVID-19 pandemic marked a paradigm shift in how consumers shop.¹ The Census Bureau of the Department of Commerce predicts this growth to continue – the third quarter of 2023 estimated an increase in e-commerce sales of 7.6% compared to Q3 the year prior.²

Although consumers can enjoy buying goods seamlessly over their screens, this growth has resulted in changes throughout warehouse and distribution industries in the U.S. to meet this growing commerce demand. In 2022, the Bureau of Labor Statistics estimated over 7 million people worked as hand laborers and material movers and predict this industry to add more than 350,000 workers (5% growth) before 2032, which is faster than average.³

With these industries welcoming an inﬂux of new employees, the safety and comfort of those joining these labor-intensive industries must be considered. Safety starts from the ground up and proper PPE such as safety footwear, can be key in protecting laborers from injuries and fatigue, while also resulting in increased productivity and aid in a more positive work culture.

Trends and material innovations in safety footwear

Safety footwear is often associated with images of work boots that are large, bulky, and heavy. However, the reality of the current safety footwear landscape is that many work shoes are now being designed with athletic silhouettes to both meet the safety and performance demands of movement intensive jobs as well as the aesthetic preference of those working in these ﬁelds. The result is footwear that seamlessly blends the protection of a traditional work boot with the lightweight ﬁt, feel, and performance of a sneaker.

These work sneaker-inspired silhouettes appear athletic, but also oﬀer the safety and performance beneﬁts that are often excellent choices for indoor work settings. Constructed with a blend of mesh and textiles, this footwear oﬀers durability in high-abrasion areas along with breathability for comfort throughout the work day. This footwear is also often non-marring which is critical for many manufacturing settings where workers must be careful to not scratch materials they may be producing. Additionally, work sneakers are often designed with TPU webbings and waterproof linings, which oﬀer added structure and stability necessary for long shifts on your feet and protection from the elements.

What to look for in safety footwear for indoor and manufacturing environments

Every job site has its own unique requirements, and indoor manufacturing and warehousing jobs are no exception. These jobs often require workers to spend long hours on their feet where activities could include standing, moving, bending, or more. Those new to this workforce may favor wearing their everyday sneakers or non-athletic safety footwear, but these shoes have not necessarily been designed with the safety and performance features required for manufacturing or warehouse environments.

Many warehouse settings require unique PPE that not only keeps workers safe, but can also provide comfort over the course of a long day of work. Before purchasing safety footwear, it is important to understand the unique hazards of a job site as well as requirements from the company or regulatory bodies such as OSHA. There is no one-size-ﬁts-all solution for safety footwear, so safety managers and supervisors are a helpful starting point for learning about the speciﬁc requirements for a job site. From there, here are a few considerations when selecting a work shoe for indoor manufacturing and warehouse environments:

There is no one-size-ﬁts-all solution for safety footwear, so safety managers and supervisors are a helpful starting point for learning about the speciﬁc requirements for a job site.

Safety Toes: Workers are often required to wear footwear with a protective toe cap to help reduce impact or crush injuries on the job. While steel and aluminum toes are well-known (and excellent options), there are also a variety of lightweight and non-metallic options. In recent years, carbon-ﬁber toes have grown in popularity. These toe caps are 15% lighter than steel and, over the course of a long shift on your feet, this reduction in weight can add up. In addition to being lightweight, carbon-ﬁber is non-metallic, which provides added convenience for workers who have to pass through metal detectors throughout the day. At my company, our safety toes are asymmetrical to provide a less obtrusive ﬁt. Additionally, these caps contour the natural shape of the foot, enabling toes and feet to ﬂex more naturally.

Cushioning: Another consideration when selecting a work shoe is its ability to cushion and support your feet. A cushioned shoe supports the foot by aiding in its alignment when it touches the ground. A cushioned shoe will not reduce the force applied on the foot, but it will increase the time it takes for that force to apply, allowing the body to adapt. To ensure a work shoe is properly cushioned, feel the midsole of the shoe. For additional cushioning, arch supports can address pain and issues related to function of the lower legs and feet, while providing additional foot alignment and function.

Slip-resistance: In work environments where grease, water, or other liquids are prevalent, it is critical for a shoe to have oil- and-slip-resistant enhanced outsoles to prevent slips, trips, and falls.

Shallow tread designs can aid with maximizing surface area contact and siped channels along the tread can quickly disburse liquids, which contributes to better surface area traction. To ensure personal safety in your work environment, look for footwear that is speciﬁcally labeled as slip-resistant.

Fit matters: For jobs that require constant moving and standing such as warehouses or manufacturing settings, properly ﬁtting safety footwear is essential when it comes to increasing productivity, preventing injuries, and oﬀering comfort. Because feet swell throughout the course of the day, try potential new shoes on after a shift when feet are naturally their largest. It is also helpful to wear the socks you would wear during a shift. Even if you believe you know your shoe size, it is worthwhile to ask a store associate for a proper sizing or ﬁt test. Shoes that are too loose can cause hazards from tripping, while shoes that are too tight can cause foot-health problems such as blisters or in-grown toenails.

Proper ﬁt extends beyond ﬁnding your right size, especially where women are concerned. This growing segment of professionals has historically been under-represented when it comes to proper ﬁtting PPE, including footwear. In the past, women in the trades have been forced to ﬁnd the smallest men’s size or settle for ill-ﬁtting footwear. Today many footwear brands are working to be more inclusive when it comes to product development for all. My company, as an example, has created a tradeswomen tested program where on-the-job feedback from women in the trades is integrated into product conception all the way through product release.

Safety starts from the ground-up

The material advancements and product developments in recent years have truly opened the aperture in the variety of safety footwear available on the market. This has resulted in PPE footwear that oﬀers a variety of safety, performance, and comfort enhancements.

For both new and existing workers in growing ﬁelds like indoor manufacturing and warehouse setting, health and safety must be prioritized and that starts from the ground-up. No two feet are alike and while diﬀerent jobs will have diﬀerent requirements, the right safety shoe will oﬀer the protection, support, and mobility to empower workers to feel comfortable on the job each step of the day.

See more articles from our March 2024 issue!