Most warehouse managers are aware of the dangers that are inherent with working at heights. Whether retrieving inventory from a high rack or using an order picker on an elevated platform, the threat of a serious fall is ever-present. Falls from heights are not just one of the main causes of injuries in warehouses; they are among the most devastating, often resulting in work stoppages, costly claims, and, most importantly, permanent effects on people. Yet, with the right strategies and technology, these incidents are preventable.

The Reality of Falls from Heights

Falls from elevated surfaces, such as elevated vehicles, mezzanines, and mezzanines account for a large portion of warehouse injuries. OSHA mandates fall protection at elevations of four feet or more in general industry settings, but meeting regulations isn’t always enough. In practice, even veteran employees can become careless or hurried, leading to neglecting to connect safety equipment. The outcome can be serious: one miscalculation at height can result in catastrophic harm or fatalities.

Warehouses are dynamic environments. Workers frequently need to reach stock stored high above the floor, using equipment like swing-reach vehicles or turret trucks. These machines are crucial for today’s warehouses, but they also create special safety challenges. A single lapse, not attaching a lanyard or improperly securing a lanyard, can have tragic results.

Traditional Fall Protection: Strengths and Shortcomings

In the past, warehouses have relied on a mix of protective rails, safety nets, and personal fall arrest solutions to protect workers performing their duties up high. Barriers and guardrails are effective on mezzanines and fixed platforms, but they cannot protect operators of mobile equipment. Personal fall arrest systems such as harnesses and lanyards are the go to solution for workers using elevated trucks. Unfortunately, these systems rely on consistent human behavior. Even the best-trained worker can forget to tether in a moment of distraction, especially during busy shifts or under tight deadlines.

Safety managers have long struggled with this human factor. Visual checks and periodic audits help, but they don't provide total assurance, especially in complex, round-the-clock facilities.

The Raymond iWarehouse Integrated Tether System: Closing the Compliance Gap

Raymond’s iWarehouse Integrated Tether System represents a significant step forward for fall prevention for warehouses where elevated work is routine. Unlike traditional systems that count on human compliance, the Integrated Tether System employs advanced wireless systems to make certain that safety rules are enforced whenever an employee uses elevated equipment.

Here’s how it works: The system requires the operator to attach a lanyard to their safety harness before the vehicle will operate at normal speed or allow the forks to elevate. If the operator is not properly tethered, the system immediately sends a series of progressive warnings including audible alarms, visual warnings on the iMONITOR display, and, if ignored, slowing the vehicle to a crawl and shutting off lift controls. This comprehensive system ensures that operators cannot work around required protocols, even unintentionally.

The Integrated Tether System is currently an option for Raymond’s Orderpicker models (5300, 5400, 5500, 5600) and Swing-Reach trucks (9600, 9700), making it a practical solution for a wide range of warehouse operations. Besides instant monitoring, the system supplies managers with compliance tracking and reporting, enabling focused coaching and proactive safety management.

Take the Next Step Toward Fall Protection

Elevated falls remain as a top safety concern for modern warehouses, but they are also one of the most avoidable. By integrating advanced solutions like the Raymond Integrated Tether System into your safety strategy, you can achieve real safety improvements, protecting your employees, your output, and your sense of security.

If you’re ready to take a proactive approach to fall protection, contact Raymond West. Our team can review your safety needs, install advanced safety systems, and build a safer, more resilient operation—one where every worker at height returns safely to the ground.

Raymond West's Boise service center serves most of Idaho, including Boise, Nampa, Meridian, Idaho Falls, Caldwell, Pocatello, Twin Falls, Post Falls and surrounding areas.

Raymond West | Boise Material Handling Equipment Supplier

743 W McGregor Ct #100
Boise, ID 83705
(800) 675-2500