Most warehouse managers are aware of the dangers that come with working at heights. Whether retrieving inventory from a high rack or manuevering an order picker on a mezzanine, 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 some of the most devastating, often resulting in downtime, expensive insurance claims, and, most importantly, long-term consequences for workers. Yet, with the right precautions and technology, these incidents are preventable.

The Reality of Falls from Heights

Falls from high locations, such as order pickers, raised work areas, and mezzanines account for a substantial number of warehouse injuries. OSHA mandates fall protection at elevations of four feet or more in general industry settings, but simply following the rules doesn’t ensure safety. In practice, even veteran employees can become overconfident or rushed, leading to neglecting to connect safety equipment. The outcome can be grave: a single miscalculation at height can result in life-altering injuries or fatalities.

Warehouses are busy settings. Employees frequently need to retrieve goods from high shelves, using equipment like swing-reach vehicles or turret trucks. These machines are essential for modern fulfillment operations, but they also introduce unique fall hazards. A single lapse, not attaching a lanyard or not fastening a harness properly, can have devastating effects.

Traditional Fall Protection: Strengths and Shortcomings

Historically, warehouses have employed a mix of safety barriers, safety nets, and personal fall arrest systems to protect workers at height. Barriers and guardrails are helpful on permanent raised surfaces, but they do not ensure the safety of workers on moving vehicles. Personal fall arrest systems such as harnesses and lanyards are the most common strategy for operators of order pickers and similar vehicles. However, these solutions rely on reliable use by staff. Even the best-trained employee can neglect to connect a harness when rushed, especially during high-pressure times or under tight deadlines.

Supervisors and safety managers have long wrestled with the challenge of human error. Spot 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: Reducing the Compliance Burden

Raymond’s iWarehouse Integrated Tether System is a major advancement in warehouse safety for warehouses where work at height is routine. Unlike traditional systems that count on human compliance, the Integrated Tether System employs wireless technology to make sure that safety standards are met each time someone operates a lift truck.

Here's what happens: The system requires the employee to attach a lanyard to their safety harness before the vehicle will function at regular speed or allow the forks to elevate. If the operator is not properly tethered, the system immediately triggers a series of progressive warnings including beeping alerts, visual warnings on the iMONITOR display, and, if unaddressed, reducing speed and disabling elevation features. This layered safety method makes sure that workers cannot work around required protocols, even unintentionally.

The Integrated Tether System is now available for Raymond’s Orderpicker models (5300, 5400, 5500, 5600) and Swing-Reach trucks (9600, 9700), making it a useful option for diverse warehouse needs. Besides real-time enforcement, the system provides managers with detailed data on tether compliance, enabling targeted training and forward-thinking risk management.

Take the Next Step Toward Fall Protection

Elevated falls are one of the most serious hazards in today’s warehouses, but they are also one of the most preventable. By adopting new tools like the Integrated Tether System, you can move beyond compliance to true risk reduction, protecting your team, your productivity, and your confidence.

If you’re ready to improve your fall prevention efforts, contact Raymond West. Our warehouse safety professionals can evaluate your warehouse hazards, install advanced safety systems, and build a safer, more resilient operation—one where every worker at height is protected on every shift.

Raymond West's Las Vegas facility serves all of the Las Vegas Valley, including Las Vegas, North Las Vegas, Henderson, Summerlin, Paradise, Spring Valley, Sunrise Manor, Enterprise, Winchester, Whitney and all surrounding areas.

Raymond West | Las Vegas Material Handling Equipment Supplier

2555 E Washburn Rd
North Las Vegas, NV 89081
(702) 651-6480