I’ve been fighting in the SCA (medieval hobbyist group) for a quarter century; I believe there are several others on the SDMB with similar experience. Not many of us wear full plate, but my understanding (backed up by my own experience wearing articulated plate armor on my legs) is that the weight isn’t really a problem. A full suit of 15th century battle armor (as opposed to specialized jousting armor) would weigh around 80 pounds. Properly distributed on the body, this much weight isn’t very restrictive for a healthy man.
Of course, hard fighting with hand-to-hand weapons is exhausting in itself. I’m 46, though, and still at it.
What’s of overriding importance is: 1) how well the articulated joints are made; and 2) how well it fits your particular body.
Making articulated plate armor (so that leg or arm protection will bend as you do) is a tricky thing; if the pieces are sized just right, and fastened together at the right points, the joint will either bind up or gap open. From what I’ve seen of actual medieval pieces in museums (and the one 16th century arm harness I got to play with), the professional armorers (living in a time when this stuff was used in actual battles) had this art down to near perfection.
But even the best-made plate armor will be a hindrance if it doesn’t fit your body. Wealthy knights would have armor made to their precise measurements, even leaving wax casts of their limbs with the armorer.
So, well-made, properly-fitted armor isn’t very restrictive – especially not if you’ve been wearing it almost every day for years of training, as would be true of the professional knights of the 15th century. This is when full plate armor reached its peak – the archetypal “knight in shining armor” that people think of. Of course, it’s also when the mounted knight was becoming less and less important as a military force in real battles, thanks to a variety of social and technological developments.
The ridiculous image of an armored knight being hoisted onto his horse with a crane probably comes from a particular Victorian music hall comedy. A fairly young man in good physical condition, in well-made, well-fitted plate armor, can run, turn cartwheels, and generally move about pretty easily. I don’t know about a 1600-meter run; I know I can’t do that with or without armor, but some of the slender, athletic young guys I know in the SCA could probably do a respectable job.
If you’re talking about previous centuries of warfare, say the 13th century, then the main form of armor – for those who could afford it – would be a long shirt of mail (“chainmail”). Lighter than you might think, and not really restrictive or burdensome if worn over a good padded undergarment. My feeling, based on my experience wearing just that (and on contemporary first-hand accounts), is that the thick padding did most of the protection from blows, with the mail preventing a weapon’s edge from getting through. You need pretty sturdy padding, and I really think overheating would be a more common problem than the weight.
Always fun to talk about this stuff. If you want some really exhaustive discussions, try www.armourarchive.org.