Most warehouse managers are aware of the dangers that are inherent with working at heights. Whether picking stock from upper shelves or using an order picker on an elevated platform, 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 some of the most serious, often resulting in lost time, high compensation costs, 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 high locations, such as order pickers, 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 veteran employees can become overconfident or hurried, leading to forgetting to use safety harnesses. The consequences are sobering: a single misstep at height can result in life-altering injuries or fatalities.

Warehouses are constantly changing workplaces. Workers frequently need to retrieve goods from high shelves, using equipment like lift trucks or turret trucks. These machines are vital to efficient warehouse work, but they also introduce unique fall hazards. A momentary lapse, not attaching a lanyard or incorrectly attaching safety equipment, can have serious consequences.

Traditional Fall Protection: Strengths and Shortcomings

In the past, warehouses have relied on a mix of guardrails, 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 lanyards and harnesses are the most common strategy for workers using elevated trucks. However, these solutions rely on reliable use by staff. Even the most conscientious employee can miss a step while distracted, especially during busy shifts or under production pressure.

Supervisors have long found it difficult to manage this risk. Spot checks and routine audits can assist, but they don't ensure everyone always follows the rules, especially in complex, round-the-clock facilities.

The Raymond iWarehouse Integrated Tether System: Compliance Made Easy

Raymond’s iWarehouse Integrated Tether System is a major advancement in warehouse safety for operations where work at height is routine. Unlike traditional systems that depend only on workers following procedures, the Integrated Tether System employs modern connectivity to make certain that safety standards are enforced whenever an employee uses elevated equipment.

Here’s how it works: The system requires the operator to attach a lanyard to their safety harness before the vehicle will move at full capacity or allow the forks to elevate. If the operator is not properly tethered, the system immediately triggers a series of escalating alerts including audible alarms, visual warnings on the iMONITOR display, and, if ignored, reducing speed and disabling elevation features. This comprehensive system ensures that employees cannot work around required protocols, even unintentionally.

The Integrated Tether System is currently 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 real-time enforcement, the system provides supervisors with compliance tracking and reporting, allowing for specific safety education and preventive safety planning.

Take the Next Step Toward Fall Protection

Elevated falls are a major risk in warehouse operations, but they are also one of the most preventable. By adding modern technology such as the Integrated Tether System to your safety program, you can achieve real safety improvements, protecting your employees, your operations, and your sense of security.

If you’re ready to improve your fall prevention efforts, contact Raymond West. Our safety experts can evaluate your warehouse hazards, bring in cutting-edge solutions, and create a more secure workplace—one where every worker at height comes down safely, every time.

Raymond West's Tucson facility serves Pima County, including Tucson, South Tucson, Marana, Oro Valley, Sahuarita and surrounding areas

Raymond West | Tucson Material Handling Equipment Supplier

Tucson Service Area
(520) 729-4222