Most warehouse managers are aware of the hazards that are inherent with working at heights. Whether retrieving inventory from a high rack or manuevering an order picker on a mezzanine, the potential of a serious fall is ever-present. Accidental falls are not just a leading cause of warehouse injuries; they are some of the most severe, often resulting in lost time, high compensation costs, and, most importantly, permanent effects on people. Yet, with the right precautions and technology, these incidents are preventable.

The Reality of Falls from Heights

Falls from high locations, such as elevated vehicles, elevated platforms, 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 lapses in tethering or harness use. The outcome can be serious: a single misstep at height can result in life-altering injuries or fatalities.

Warehouses are busy settings. Workers frequently need to access inventory stored several levels above the ground, 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, not attaching a lanyard or improperly securing a lanyard, can have serious consequences.

Ordinary Fall Protection: Strengths and Shortcomings

In the past, warehouses have employed a mix of safety barriers, safety nets, and personal fall arrest systems to protect employees performing their duties up high. Guardrails and barriers are useful for fixed elevated areas, but they do not protect workers on order pickers. Personal fall arrest systems such as harnesses and lanyards are the standard for operators of order pickers and similar vehicles. Unfortunately, these solutions depend on reliable use by staff. Even the most conscientious worker can forget to tether in a moment of distraction, particularly during busy shifts 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 ensure everyone always follows the rules, 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 warehouse environments where elevated work is routine. In contrast to traditional systems that count on human compliance, the Integrated Tether System uses advanced wireless systems to make certain that safety standards are enforced whenever an employee uses elevated equipment.

Here's what happens: The system requires the worker to secure a tether to their harness before the vehicle will move at full capacity or allow the forks to elevate. In the event that the worker isn't tethered correctly, the system instantly sends a series of progressive warnings including sound warnings, on-screen messages, and, if ignored, slowing the vehicle to a crawl and shutting off lift controls. This layered safety method makes sure that workers cannot skip safety steps, 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. In addition to instant monitoring, the system supplies supervisors with detailed data on tether compliance, enabling targeted training and proactive safety management.

Take the Next Step Toward Fall Protection

Falls from heights remain as a top safety concern for modern warehouses, but they are also among the most avoidable. By adopting new tools like the Integrated Tether System, you can go further than just meeting regulations, protecting your employees, your productivity, 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 create a more secure workplace—one where every worker at height returns safely to the ground.

Raymond West's Riverside service area includes Redlands, Colton, Rialto, Bloomington, Moreno Valley, Hemet, Perris, Lake Elsinore, Menifee, Coachella Valley and all surrounding areas.

Raymond West | Riverside Material Handling Equipment Supplier

Riverside, CA
(951) 384-2444