Which Is Better for the Industrial Sector? Work Shoes with Steel Toe Caps or Composite Toe Caps

Industrial operations involve working with heavy machinery and equipment,  hazardous substances and electricity, and production activities generate noise. Personal protective equipment (PPE) is therefore indispensable in this industry. In addition to protective clothing, safety glasses, helmets and hearing protection, safety shoes in particular are also part of the occupational safety concept for which company management is responsible. And as we have already explained elsewhere, under DGUV Rules 112-191, a shoe is only considered a “safety shoe” if it has a toe cap that can withstand a force of at least 100 joules. Today, protective toe caps are also made from different materials, each of which offers various advantages and disadvantages depending on the area of use. Reason enough for Shoes For Crews to take a closer look at the subject in this article.

Temperature range as a selection criterion

Better safe than sorry—the familiar saying applies nowhere more than in industries where employees are exposed to a wide range of environmental conditions. Examples include cold rooms in beverage and food production, foundry workstations in the metal industry, workstations directly at blast furnaces in the steel industry, high-temperature workstations at hot rolling mills, cleanrooms, and more. These are extreme examples, but they illustrate the temperatures to which safety shoes, and therefore their toe caps, are exposed. For this reason, it is worth examining the characteristics of the various materials individually.

Steel toe caps

In common usage, toe caps are still often referred to generally as “steel caps,” due to the fact that the first caps of this type were made of steel. The material was the obvious choice: it is robust and inexpensive. Below, we have summarised the advantages and disadvantages for you:

Advantages:

1. High level of protection: Steel toe caps are considered extremely robust and offer excellent protection against severe impact and crushing injuries. They are ideal for environments where heavy objects may drop and/or fall onto feet.
2. Durability: Work shoes with steel toe caps are known for their durability and their ability to withstand heavy loads over extended periods.
3. Heat resistance: Steel is naturally heat-resistant, meaning safety shoes with steel toe caps can also be used in high-temperature environments without compromising their protective performance.

Disadvantages:

1. High weight: Steel toe caps make shoes heavier, which can lead to increased leg fatigue, particularly during long working days.
2. Electrical conductivity: In some cases, the electrical conductivity of steel toe caps can be a problem, particularly in environments where electrical hazards exist.

Plastic/composite toe caps

This type of toe cap is made from plastic reinforced with fibres. Compared with steel toe caps, they offer the following advantages and disadvantages:

Advantages:

1. Low weight: Plastic/composite toe caps are significantly lighter than steel toe caps, increasing wearer comfort and reducing leg fatigue, particularly during long working hours.
2. Non-electrically conductive: Unlike steel, plastic toe caps are non-conductive, meaning they do not pose an electrical hazard.
3. Versatility: They can be manufactured in various shapes and therefore offer greater versatility in terms of design and fit.
4. Cold protection: Plastic/composite material absorbs significantly less, if any, cold compared to steel, making the temperature inside the shoe more comfortable in winter. 

Disadvantages:

1. Shorter lifespan: Under extreme conditions, they may wear out or break more quickly over time, resulting in a shorter lifespan for work shoes compared with those featuring  steel toe caps.
2. Size: They are significantly thicker than metal toe caps. The straightforward explanation is that all caps must meet the same requirements under EN ISO 20345, and plastic is not as strong as metal at the same thickness.

The type of operation is decisive

Now that we know the advantages and disadvantages of both materials, it is clear that there is no—as the English expression goes—one-size-fits-all solution, in other words, no universal solution. Rather, it depends on the type of operation and its environmental conditions. As mentioned at the outset, heavy industry has many workplaces that contend with very high ambient temperatures. Think of metal foundries. Safety shoes with steel toe caps are best suited here because steel is heat-resistant, does not deform and thus ensures safety. However, if your employees work in cold-storage facilities or in environments where electrical hazards exist, plastic/composite toe caps are recommended because plastic does not absorb cold and is not electrically conductive. As you can see, there is the right solution for every area, and we at Shoes For Crews can help you make the right choice. Our dedicated customer advisors will be happy to assist you and can recommend exactly the right shoe for your business. Contact us today; your employees will thank you for being equipped with safe, comfortable and stylish work shoes.