If you're a warehouse manager, you know the risks that come with elevated work. Whether retrieving inventory from a high rack or using an order picker on an elevated platform, the threat of a catostrophic fall is constantly present. Falls from heights are not just one of the main causes of injuries in warehouses; they are some of the most serious, often resulting in work stoppages, costly claims, and, most importantly, permanent effects on people. Yet, with the right approaches and technology, these incidents are avoidable.

The Reality of Falls from Heights

Falls from raised platforms, 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 compliance alone does not guarantee safety. In practice, even experienced operators can become overconfident or pressed for time, leading to neglecting to connect safety equipment. The consequences are serious: one miscalculation at height can result in catastrophic harm or fatalities.

Warehouses are constantly changing workplaces. Workers are often required to reach stock stored high above the floor, using equipment like lift trucks or turret trucks. These machines are crucial for today’s warehouses, but they also bring new risks for falls. A momentary lapse, failing to secure safety gear or improperly securing a lanyard, can have serious consequences.

Ordinary Fall Protection: Strengths and Shortcomings

In the past, warehouses have employed a mix of protective rails, safety nets, and personal fall arrest systems to protect workers at height. Guardrails and barriers are effective on mezzanines and fixed platforms, but they cannot protect workers on moving vehicles. Personal fall arrest systems such as harnesses and lanyards are the go to solution for operators of order pickers and similar vehicles. Unfortunately, these systems rely on reliable use by staff. Even the most conscientious employee can miss a step while distracted, especially during peak periods or under demanding workloads.

Supervisors have long found it difficult to manage this risk. Visual checks and routine audits help, but they cannot guarantee 100% compliance, 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 major advancement in warehouse safety for warehouse environments where work at height is routine. In contrast to traditional systems that count on human compliance, the Integrated Tether System employs wireless technology to ensure that safety protocols are met each time someone operates a lift truck.

It works in the following way: The system requires the operator to secure a tether to their harness before the vehicle will operate at normal speed or allow the forks to elevate. In the event that the worker isn't tethered correctly, the system instantly sends a series of increasing notifications including sound warnings, on-screen messages, and, if unaddressed, reducing speed and disabling elevation features. This multi-layered approach makes sure that workers cannot work around required protocols, even unintentionally.

The Integrated Tether System is currently available 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 real-time monitoring, the system supplies managers with detailed data on tether compliance, enabling specific safety education and proactive safety management.

Take the Next Step Toward Fall Protection

Falls from heights remain as one of the most serious hazards in today’s warehouses, but they are also one of the most preventable. By integrating advanced solutions like the Raymond Integrated Tether System into your safety strategy, you can move beyond compliance to true risk reduction, protecting your team, your productivity, and your sense of security.

If you’re ready to take a proactive approach to fall protection, contact Raymond West. Our warehouse safety professionals can evaluate your warehouse hazards, implement the latest technology, and create a more secure workplace—one where every worker at height comes down safely, every time.

Raymond's Seattle service operation includes most of Western Washington, including Seattle, Bellevue, Kirkland, Redmond, Bothell, Woodinville, Lynnwood, Everett, Tukwila, Renton, SeaTac, Burien, Kent, Federal Way, Fife, Sumner, Auburn, Tacoma, Lakewood, Puyallup, Olympia, Lacey and surrounding areas.

Raymond West | Seattle Material Handling Equipment Supplier

6607 S 287th St
Auburn, WA 98001
(253) 333-2100