If you're a warehouse manager, you know the risks that are inherent with elevated work. Whether retrieving inventory from a high rack or manuevering an order picker on a mezzanine, the threat of a serious fall is always looming. 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, high compensation costs, and, most importantly, permanent effects on people. Yet, with the right strategies and technology, these incidents are able to be prevented.

The Dangers of Elevated Work

Falls from high locations, such as lift trucks, elevated platforms, 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 rushed, leading to lapses in tethering or harness use. The consequences are serious: one miscalculation at height can result in significant bodily harm or fatalities.

Warehouses are dynamic environments. Workers frequently need to access inventory stored several levels above the ground, using equipment like order pickers or turret trucks. These machines are vital to efficient warehouse work, but they also introduce unique fall hazards. A single lapse, not attaching a lanyard or incorrectly attaching safety equipment, can have serious consequences.

Ordinary Fall Protection: Strengths and Shortcomings

In the past, warehouses have employed a mix of guardrails, safety nets, and personal fall arrest systems to protect workers performing their duties up high. Barriers and guardrails are useful for fixed elevated areas, but they cannot protect workers on order pickers. Personal fall arrest systems such as lanyards and harnesses are the standard for employees on mobile lifts. However, these solutions rely on reliable use by staff. Even the most conscientious employee can miss a step while distracted, particularly during peak periods or under production pressure.

Supervisors and safety managers have long found it difficult to manage this risk. Spot checks and routine audits help, but they cannot guarantee 100% compliance, especially in large or multi-shift operations.

The Raymond iWarehouse Integrated Tether System: Compliance Made Easy

Raymond’s iWarehouse Integrated Tether System represents a significant step forward for fall prevention for operations where elevated work is the norm. In contrast to traditional systems that count on human compliance, the Integrated Tether System employs advanced wireless systems to make sure that safety rules are met each time someone operates a lift truck.

It works in the following way: 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. In the event that the worker isn't tethered correctly, the system immediately triggers a series of escalating alerts including audible alarms, flashing signals on the display, and, if ignored, automatic reduction of the vehicle’s speed to a crawl and disabling of lift functions. This comprehensive system makes sure 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 versatile choice for many facilities. Besides real-time enforcement, the system provides managers 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 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 team, your operations, and your confidence.

If you’re ready to make safety a priority, contact Raymond West. Our safety experts can help you assess your current risks, install advanced safety systems, and create a more secure workplace—one where every worker at height comes down safely, every time.

Raymond West's Phoenix facility serves the entire Phoenix Metro area, including Phoenix, Tempe, Mesa, Gilbert, Chandler, Scottsdale, Glendale, Goodyear, Tolleson, Peoria and all surrounding areas.

Raymond West | Phoenix Material Handling Equipment Supplier

2659 E Magnolia St
Phoenix, AZ 85034
(602) 275-2228