The Frustrating Mystery of Callus Build-Up
As a podiatrist, one of the most common concerns I hear from patients is callus build-up on the feet. Many people think of calluses as a normal part of life—something that comes with wearing shoes or walking a lot. But for some, calluses can become painful, unsightly, and persistent. For one of my patients, Sarah, calluses were more than just a minor nuisance; they were affecting her ability to enjoy her active lifestyle.
Despite trying numerous over-the-counter treatments and pedicures, Sarah’s calluses only seemed to get worse. This led me to believe there was more going on beneath the surface. After a thorough examination, I discovered that her foot biomechanics were contributing to the problem. What followed was a detailed exploration into the pathophysiology of callus build-up and how correcting her biomechanics led to remarkable improvement.
What Are Calluses and How Do They Form?
Before diving deeper into biomechanics, let’s start with the basics: what exactly are calluses? Calluses are thickened, hardened areas of skin that form in response to pressure or friction. They are a natural protective mechanism, meant to shield the skin from damage caused by repeated stress.
Callus formation occurs when the skin is exposed to excessive pressure or friction over time. The body compensates by producing more layers of skin in these areas, creating a thick, tough barrier. While calluses may seem harmless, they can cause discomfort and pain when left unchecked, and they may be a sign of an underlying issue with your foot mechanics.
The Pathophysiology of Callus Formation: Why It Happens
Calluses form due to hyperkeratosis—an increase in the production of keratin, a protein that forms the outer layer of skin. When the skin is subjected to repetitive pressure or friction, the body responds by thickening the skin in those areas. This is the body’s way of preventing injury, but when the stress is ongoing, the calluses can become large and uncomfortable.
The role of pressure and friction in callus formation is relatively straightforward, but what’s less understood is why some people form them more easily than others. The answer often lies in foot biomechanics.
How Foot Biomechanics Contribute to Callus Formation
Foot biomechanics refers to how your foot moves during walking, running, and standing. It encompasses the alignment and function of the bones, muscles, tendons, and ligaments in the feet. If your foot biomechanics are misaligned, it can cause uneven distribution of pressure across the foot, which leads to excess friction in certain areas.
For instance, when Sarah came to see me, I quickly noticed that her foot was overpronating—a common condition where the foot rolls inward excessively with each step. This misalignment caused excessive pressure on the inner arch and the ball of her foot, leading to callus build-up in those areas. Over time, this uneven distribution of weight creates friction, which thickens the skin and forms calluses.
Other biomechanical issues that can contribute to callus build-up include:
- Underpronation (Supination): This occurs when the foot doesn’t roll inward enough, placing pressure on the outer part of the foot.
- Flat feet: Without a proper arch, the foot lacks the natural shock-absorbing function, leading to increased pressure on certain areas.
- High arches: Limited surface contact with the ground forces pressure onto smaller areas of the foot, often resulting in callus build up.
The Biomechanics of Overpronation and Its Impact on the Feet
Overpronation is one of the most common contributors to callus build-up, and it’s something I see frequently in the clinic. In Sarah’s case, her foot was rolling inward too much, which created an imbalance in pressure distribution. As a result, she was experiencing significant friction on the balls of her feet, leading to thickened, painful calluses.
Over time, overpronation can also contribute to other foot conditions such as Plantar fasciitis, Achilles tendinopathy, and Bunions (hallux valgus). These conditions often go hand-in-hand with callus build-up, as the foot compensates for misalignment by shifting pressure to other areas.
The Role of Orthotics in Correcting Biomechanics and Reducing Calluses
Once we identified Sarah’s overpronation as the main cause of her calluses, I recommended a pair of off-the-shelf insoles as a first-line solution. While custom-made orthotics can be incredibly beneficial for individuals with significant biomechanics issues, I always emphasise the importance of a biomechanics assessment before prescribing them. This assessment ensures that any prescribed orthotics are precisely tailored to a patient’s specific needs.
In Sarah’s case, because she had not yet undergone a full biomechanical assessment, the off-the-shelf insoles were an appropriate option to start with. These insoles can provide some relief by offering added support to her arches, redistributing pressure across her foot, and minimizing the friction that was causing the calluses. Off-the-shelf insoles can certainly provide a supportive foundation for those who need relief from pressure-related conditions like calluses.
If we had moved forward with custom orthotics, they would have been designed based on the results of the biomechanical assessment to target her specific foot misalignment. Phits 3D Custom orthotics are designed to support proper foot function and help redistribute pressure in a way that minimizes friction, which in turn can prevent the development of painful calluses over time.
A biomechanical assessment is essential to determine the underlying foot mechanics before recommending custom orthotics, ensuring that the solution is tailored specifically to each patient’s unique needs.




Other Treatments to Prevent and Manage Callus Build-Up
While custom orthotics were instrumental in treating Sarah’s calluses, there are other treatments and preventive measures that can help reduce or eliminate callus formation:
- Biomechanics Assessments: A thorough foot assessment can help identify any underlying biomechanical issues that may be contributing to callus build-up. This allows for a tailored treatment plan.
- Shockwave Therapy: For patients with chronic foot pain due to biomechanical issues, shockwave therapy can be an effective treatment to reduce inflammation and pain.
- Laser Therapy: MLS® Laser Therapy is another treatment option for reducing pain and inflammation associated with calluses. It promotes faster healing and tissue repair by stimulating blood flow and accelerating cellular processes. If your calluses are causing persistent pain or if other treatments haven’t been effective, laser therapy can provide relief and support healing.
- Foot Exercises: Strengthening the muscles and tendons in the foot can improve overall foot function, reduce pressure on specific areas, and prevent the formation of calluses.
- Regular Foot Care: Moisturising the feet, using foot scrubs, and visiting a podiatrist for professional callus removal can help manage the condition. However, it’s important to address the root cause to prevent recurrence.


Preventing Future Callus Build-Up: What You Can Do
If you are dealing with calluses, it is important to understand that they may be a symptom of poor foot biomechanics. The first step in addressing them is to assess how your feet move and how pressure is distributed. Here are a few preventive tips:
- Wear Supportive Footwear: Shoes that fit well and offer proper arch support can help correct alignment and prevent excess pressure on certain parts of the foot. One pair of shoes I highly recommend for comfort and support is the Brooks Adrenaline GTS24. They offer excellent cushioning, support for overpronation, and help reduce pressure on the feet—ideal for preventing callus build-up. I’ve written a detailed review on these shoes, which you can check out on my Facebook page here.

- Strengthen Foot Muscles: Regular foot exercises can improve strength and flexibility, promoting better biomechanics and reducing the risk of calluses.
- Get Custom Orthotics: If you have foot alignment issues like overpronation custom orthotics can provide the support you need to reduce callus build-up.
- Maintain a Foot Care Routine: Keep your feet hydrated and exfoliate regularly to prevent calluses from becoming too thick and painful. If you are unsure about the best foot care routine or need professional help with managing calluses, I encourage you to book an appointment at the clinic for a personalised consultation. Together, we can find the right solution for your feet!
👉 Book your appointment here
Addressing the Root Cause of Calluses
Sarah’s experience highlights the importance of understanding the pathophysiology of callus build-up and how foot biomechanics play a crucial role in the formation of calluses. By addressing the underlying biomechanical issues, we can prevent the recurrence of painful calluses and improve overall foot health.
If you are struggling with callus build-up or experiencing discomfort, don’t ignore the signs. Book a consultation today to undergo a comprehensive biomechanical assessment and find a solution tailored to your needs. Your feet deserve to feel their best, and we are here to help make that happen.
For more information on foot biomechanics and how they affect your foot health, visit www.quantumfootcare.co.uk.