Nothing ruins a workday faster than ill-fitting boots. Too tight and you're dealing with pinched toes, blisters, and aching feet. Too loose and your heel slips with every step, causing fatigue and instability. Getting the right fit isn't complicated, but it does require more attention than most people give it.

This guide walks you through everything you need to know about finding work boots that fit properly—from measuring your feet at home to knowing what to look for when trying boots on in store.

Why Proper Fit Matters

Beyond comfort, proper fit directly affects safety and health. Boots that don't fit correctly can cause:

  • Blisters and hot spots: Both too-tight and too-loose boots create friction that damages skin
  • Foot deformities: Long-term wear of tight boots can cause bunions, hammertoes, and ingrown toenails
  • Posture problems: Poor-fitting boots change how you walk, potentially causing knee, hip, and back issues
  • Fatigue: Your muscles work harder to compensate for unstable or uncomfortable footwear
  • Safety hazards: Loose boots can catch on equipment, and unstable footing increases fall risk

Measuring Your Feet at Home

Before shopping, measure your feet accurately. This gives you a starting point and helps when ordering online.

When to Measure

Measure your feet in the afternoon or evening. Feet swell throughout the day, and measuring when they're at their largest ensures boots won't become too tight during work shifts.

How to Measure

  1. Wear the type of socks you'll use with your work boots
  2. Stand on a piece of paper on a hard floor (not carpet)
  3. Trace around your foot, keeping the pen perpendicular to the paper
  4. Measure from the heel to the longest toe—this is your foot length
  5. Measure the widest part of the tracing—this is your foot width
  6. Repeat for the other foot—most people have slightly different sized feet
Important

Always fit boots to your larger foot. If your feet are significantly different sizes, you may need to buy two different sizes or use insoles or heel grips to adjust fit in one boot.

Understanding Size Charts

Work boot sizing can be confusing because different countries use different systems, and even within Australia, sizing can vary between brands.

Australian vs US vs UK Sizing

Many work boot brands use US sizing, which typically runs about half to one size larger than Australian sizing. UK sizing is similar to Australian. Always check which sizing system a brand uses before ordering.

Brand Variations

Even within the same sizing system, boots can fit differently between brands. Some brands run large, others run small, and some run narrow or wide compared to average. Reading reviews mentioning fit can help anticipate these variations.

Width Considerations

Length isn't the only measurement that matters. Standard width boots don't suit everyone—some workers need wide or narrow fittings. Width is typically designated as:

  • B or N: Narrow
  • D or M: Standard/Medium (most common)
  • E or W: Wide
  • EE or 2E: Extra Wide

Not all retailers stock width options, so you may need to seek out specialist suppliers if standard widths don't work for you.

Key Takeaway
Your shoe size in one brand doesn't automatically transfer to another. Treat every brand as potentially different and always try before committing when possible.

Trying on Work Boots

If possible, try boots on in person. This gives you the best chance of finding a proper fit. Here's what to check:

Length Check

When standing with weight on your feet, you should have approximately a thumb's width (about 1cm) of space between your longest toe and the end of the boot. This accommodates foot swell during the day and prevents toes hitting the front when walking downhill or kneeling.

Width Check

Your foot should feel snug but not squeezed across the ball of the foot (the widest part). You shouldn't feel pressure on the sides of your toes, and there shouldn't be significant empty space at the sides.

Heel Check

Your heel should feel secure in the heel cup with minimal slipping when you walk. Some new boot slip is normal and will reduce after break-in, but excessive heel movement indicates poor fit.

Arch Check

The boot's arch support should align with your natural arch. If the arch feels too far forward or back, the boot won't support your foot properly. This is particularly important if you have high or flat arches.

Toe Box Check

Wiggle your toes—you should have room to move them freely. For steel or composite toe boots, check that the toe cap doesn't press down on your toes when you flex forward.

Walk Test

Walk around the store for at least ten minutes. Boots should feel comfortable from the start, though they'll soften further during break-in. Pay attention to any rubbing, pinching, or instability.

Online Buying Tips

When buying online is your only option, these strategies reduce the risk of fit problems:

  • Check return policies: Ensure you can return boots that don't fit
  • Read fit reviews: Look for comments about whether boots run large, small, wide, or narrow
  • Order multiple sizes: If returns are free, order two sizes and return the one that doesn't fit
  • Contact customer service: Ask about typical fit for your foot measurements
  • Measure your current boots: Compare the insole length of boots that fit well to size charts

Adjusting Fit

Sometimes boots are close to right but not quite perfect. Minor adjustments can help:

For Boots That Are Slightly Large

  • Add thicker insoles to take up volume
  • Wear thicker socks
  • Use heel grips or heel pads to prevent slipping
  • Try tongue pads to adjust fit at the top of the foot

For Boots That Are Slightly Tight

  • Use thinner insoles
  • Wear thinner socks
  • Use boot stretchers on specific tight spots
  • Have a cobbler professionally stretch problem areas
Limits to Adjustment

While minor fit adjustments are possible, boots that are fundamentally the wrong size should be returned. You can't effectively make boots a full size larger or smaller, and trying to force a poor fit will only cause problems.

Special Fitting Considerations

Orthotic Wearers

If you wear custom orthotics, bring them when trying on boots. You may need boots with removable insoles and possibly a half size larger to accommodate the orthotic volume.

Wide or Narrow Feet

Don't try to compensate for width issues by going up or down in length—this creates its own problems. Seek out brands that offer width options or specialise in wide fittings.

High Volume Feet

Some feet are high volume (thick from top to bottom) even with normal length and width. Look for boots with adjustable lacing that can accommodate this, or seek out brands known for roomier fits.

For personalised boot recommendations based on your specific needs, try our boot finder quiz. Once you've found boots that fit, check our break-in guide to make the transition comfortable.

MT

Mike Thompson

Founder & Lead Reviewer

After decades of struggling with wide feet and work boot fitting, Mike has become an evangelist for proper sizing. He's fitted hundreds of boots and knows from experience that the right size makes all the difference.