When to replace safety footwear and how to extend its service life

Safety footwear is personal protective equipment designed to protect against specific hazards.

However, its protective capacity may diminish due to use, wear and tear, environmental conditions or inadequate maintenance.

There is no single lifespan that applies to all models and users. The lifespan of safety footwear depends on factors such as frequency of use, the working environment, materials, exposure to water, heat or chemicals, and the quality of maintenance.

Therefore, rather than focusing solely on age, it is essential to inspect their condition regularly.

Shelf life and service life of safety footwear: they are not the same thing

Shelf life during storage refers to the period during which the footwear can retain its characteristics before use, provided it is kept under normal temperature and humidity conditions.

As a general guide, in accordance with Recommendation 10.082 Revision 1 of CEN/TC 161/VG 10, when footwear is stored under normal conditions (temperature and relative humidity), the shelf life will normally be:

4–5 years from the date of manufacture for footwear with a polyurethane sole.
10 years from the date of manufacture for footwear with rubber soles. The date of manufacture can be found on the marking on the sole, the tongue or the upper, depending on the model.

These periods do not determine how long the footwear will last once in use. Boots used daily in demanding conditions may need to be replaced much sooner. The actual service life will always depend on their condition, working conditions and the instructions provided by the manufacturer.

Signs indicating that the footwear should be inspected or replaced

Before starting the working day, it is advisable to carry out a quick visual check, paying attention to the following points.

Sole

Footwear must be discarded or assessed if it shows:

Significant wear to the tread pattern or relief.
Cracks, cuts or punctures.
Separation between the sole and the rest of the footwear.
Deformations caused by heat or contact with corrosive substances.
Obvious loss of stability or grip.

An excessively worn sole can reduce grip and compromise other aspects of the footwear’s performance.

Upper, seams and fastenings

The outer material, seams, laces, zips and any other fastening systems should also be checked.

Tears, burns, severe abrasions or deformations may indicate that the integrity of the footwear is compromised. The fastening system must keep the foot properly secured throughout the working day.

Safety toe cap

If the footwear has sustained a significant impact or shows deformation in the toe cap area, it must be taken out of service and assessed. Although the damage may not always be visible externally, the protective element may have lost its effectiveness.

Insole and puncture protection

A severely deformed, torn or flattened insole can affect the fit and comfort. This removable insole should not be confused with the puncture protection feature integrated into certain models.

When footwear is supplied with a removable insole, it has been tested with that insole. Therefore, it should only be replaced with a compatible insole recommended by the manufacturer. Adding or changing components without checking their compatibility may alter the certified performance.

Lining and interior

It is advisable to check the interior manually for:

Tears or wear and tear on the lining.
Creases or deformations.
Hard elements or sharp edges that could cause injury.
Persistent dampness or hygiene issues.

Situations requiring special caution

The footwear must no longer be used if there is reasonable doubt regarding its protective capacity, particularly after:

A significant impact or crushing incident.
A puncture or cut.
Accidental exposure to chemicals.
Contact with temperatures higher than those specified for the model.
Significant deformation.
The detachment of any of its components.

It is not advisable to carry out DIY repairs on parts that affect protection. Any repairs must follow the manufacturer’s instructions and ensure that the characteristics of the PPE are not altered.

For footwear designed for specific risks – such as firefighting, electrical work, foundry work, welding, chainsaw use or ESD environments, amongst others – the inspection and replacement procedures corresponding to the model, its certification and the workplace risk assessment must also be followed.

How to extend their lifespan without compromising protection

Proper maintenance helps to preserve footwear, but should never be used to prolong the use of footwear that is no longer fit for purpose.

The main recommendations are:

Clean the upper and sole regularly.
Remove mud, dust and any stuck-on substances after work.
Allow damp footwear to dry naturally.
Do not place them near stoves, radiators, fireplaces or hot-air dryers.
Store them in a dry, well-ventilated place.
Air them out whenever possible.
Alternate between two pairs when the footwear is subject to heavy use or high levels of perspiration.
Change your socks daily.
Use only cleaning and maintenance products suitable for the materials.
Do not share or reuse another person’s footwear.

For leather footwear, it is advisable to apply a natural, water-repellent cream and avoid products containing waxes or oils that may block the material’s pores.

Common mistakes that can reduce their lifespan

Practices that can cause premature wear and tear on footwear include:

Drying them using a direct heat source.
Storing them whilst wet or inside a sealed bag.
Using harsh cleaning products.
Replacing the insole with one that is not compatible.
Ignoring small gaps, cuts or flaws in the seams.
Continuing to use them after a significant impact without assessing the damage.
Using them in situations involving risks for which they are not certified.

Before choosing or replacing a model, it is important to check its classification and markings. You can consult our guide on safety footwear regulations.

Quick inspection checklist

Before using the footwear, check:

Does the sole still have sufficient tread?
Are there any cracks, cuts or areas where the sole has come away?
Does the upper show any significant deformation, burns or abrasions?
Do the seams and fastening systems work properly?
Has the toe cap suffered any impact?
Is the insole misshapen or damaged?
Is the inner lining intact?
Do the shoes still fit and support the foot properly?
Have they been exposed to any substances that could affect their materials?

If any answer raises doubts, the footwear must be temporarily withdrawn from use and inspected in accordance with the manufacturer’s instructions and the company’s health and safety procedures.

A decision based on condition and risk

Replacing safety footwear at the right time does not depend solely on its appearance or on a specific date. Actual wear and tear, conditions of use and the risks against which it is intended to protect must be assessed.

The wearer should carry out frequent checks, whilst those responsible for health and safety and procurement should establish criteria for inspection, replacement and traceability. In case of any doubt, the risk assessment, the model’s technical documentation and the manufacturer’s instructions should take precedence.

Consult the FAL safety footwear catalogue and compatible accessories to select suitable solutions for every working environment.