Accidents during paving jobs can happen fast. For Dakota, a screed operator in East Wisconsin, one split-second nearly turned into a life-changing injury. Instead, his HeatArmor™ work boots took the hit – and barely left a mark.  

The incident: Nearly four tons of force to the foot 

Dakota has over a decade of experience in construction, including five years of paving-specific work.  

During one particular job he was working near the paver as the operator prepared to lower the screed – the 7,800-lb plate that levels and compacts the asphalt.  

Everything was routine. Then, in an instant, Dakota saw the screed dropping directly onto his toes.  

He was able to shout to the operator, but the screed still made contact – and not lightly. The front of the boots absorbed the blow long enough for the operator to reverse the move, preventing a catastrophic injury. When Dakota pulled his foot out, he realized what had just happened: without the right boots, he would have lost multiple toes.  

The reality: Not all companies require PPE 

Most asphalt companies don’t require a safety toe in paving operations, despite working with heavy equipment and large machinery. Dakota wasn’t doing anything wrong on the day of the near-catastrophe that occurred – he followed proper protocol. But the job environment leaves zero margin for error, and sometimes “routine” tasks turn hazardous without warning.  

That’s why it’s best to be prepared for the worst. Dakota knew the risks and made the decision to get work boots with a safety toe for his shifts. But not just any safety toe – a composite safety toe from HexArmor®. 

His decision to get added safety paid off when he needed it most. After his boots took the force of the screed, the leather of the boot tore slightly but the composite toe cap held – and he walked away with all of his toes. As Dakota put it, “It’s crazy how quickly accidents can happen.” Not to mention what could have happened without the right work boots.

The truth: The type of safety toe matters 

Traditional steel-toe boots can permanently deform under extreme or point-load impact, potentially transferring force to the toes. Composite safety toes are engineered to absorb and distribute impact energy differently, helping maintain protective space inside the boot. 

In Dakota’s case, his HeatArmor® asphalt boots from HexArmor® did exactly what they were designed to do. The layers over the toes were damaged, but the structure of the boot stayed intact. He’s still using those same boots to finish the season. 

Dakota said it best: 

“...if it wasn't for your boots, I would have lost some toes. The only damage is to the fabric layers! I'll definitely be grabbing a new pair for next year. Thanks again.” 

This incident reinforces what workers in road construction know all too well: even when you’re trained, experienced, and cautious, heavy equipment doesn’t leave room for second chances. Ensuring you have the right protective equipment as a last line of defense on the job matters – and sometimes that means going above and beyond job requirements. 

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