Most warehouse managers are aware of the dangers that come with working at heights. Whether accessing goods stored up high or manuevering an order picker on a mezzanine, the potential of a serious fall is constantly present. Falls from heights are not just a leading cause of warehouse injuries; they are among the most devastating, often resulting in lost time, costly claims, and, most importantly, lasting human impact. Yet, with the right strategies and technology, these incidents are able to be prevented.

The Reality of Falls from Heights

Falls from high locations, such as elevated vehicles, mezzanines, and mezzanines account for a significant share 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 experienced operators can become careless or pressed for time, leading to lapses in tethering or harness use. The outcome can be serious: a single miscalculation at height can result in significant bodily harm or fatalities.

Warehouses are busy settings. Workers are often required to retrieve goods from high shelves, using equipment like lift trucks or turret trucks. These machines are crucial for today’s warehouses, but they also create special safety challenges. A single lapse, failing to secure safety gear or incorrectly attaching safety equipment, can have serious consequences.

Traditional Fall Protection: Strengths and Shortcomings

Historically, warehouses have relied on a mix of protective rails, safety nets, and personal fall arrest systems to protect employees at height. Guardrails and barriers are useful for fixed elevated areas, but they cannot ensure the safety of operators of order pickers. Personal fall arrest systems such as harnesses and lanyards are the go to solution for workers using elevated trucks. However, these solutions rely on reliable use by staff. Even the best-trained worker can miss a step while distracted, particularly during busy shifts or under tight deadlines.

Supervisors have long found it difficult to manage this risk. Visual checks and routine audits can assist, but they cannot ensure everyone always follows the rules, especially in large or multi-shift operations.

The Raymond iWarehouse Integrated Tether System: Reducing the Compliance Burden

Raymond’s iWarehouse Integrated Tether System represents a leap forward in fall protection for operations where elevated work is common. In contrast to traditional systems that depend only on workers following procedures, the Integrated Tether System uses wireless technology to make sure that safety rules are met each time someone operates a lift truck.

Here’s how it works: The system requires the employee to connect a self-retracting lanyard to their 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 increasing notifications including sound warnings, flashing signals on the display, and, if ignored, automatic reduction of the vehicle’s speed to a crawl and disabling of lift functions. This multi-layered approach ensures that workers cannot bypass safety procedures, even unintentionally.

The Integrated Tether System is now an option 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 supplies supervisors with compliance tracking and reporting, allowing for specific safety education and forward-thinking risk management.

Take the Next Step Toward Fall Protection

Falls from heights are one of the most serious hazards in today’s warehouses, but they are also one of the most avoidable. By adopting new tools like the Integrated Tether System, you can achieve real safety improvements, protecting your team, your operations, and your peace of mind.

If you’re ready to make safety a priority, contact Raymond West. Our warehouse safety professionals can help you assess your current risks, bring in cutting-edge solutions, and build a safer, more resilient operation—one where every worker at height comes down safely, every time.

Raymond West's Stockton facility serves much of the northern Central Valley, including Stockton, Lathrop, Lodi, Tracy, Modesto, and Merced.

Raymond West | Stockton Material Handling Equipment Supplier

19107 Christopher Way
Lathrop, CA 95330
(800) 675-2500