To create a comprehensive OSHA-compliant safety manual, consider including these components:

1. Hazard Communication Program: This includes Safety Data Sheets (SDS) for all hazardous materials used in the workplace 1, 2, 4, 5, 6, 8, 9, 11, 15, 16, 18, 19. Ensure employees know how to access and understand the information on the SDS, including potential hazards, first-aid measures, and proper handling and storage procedures 13, 18, 19.
2. Personal Protective Equipment (PPE) Program: Detail the required PPE for various tasks and chemicals, such as impervious gloves, eye protection (safety goggles or face shields), and suitable protective clothing 1, 2, 3, 4, 5, 6, 8, 9, 10, 11, 12, 15. Also, specify when a NIOSH-approved respirator is needed, especially in poorly ventilated areas or when exposure limits may be exceeded 10, 12, 15. The program should align with OSHA's respirator standard (29 CFR 1910.134) and ANSI's standard for respiratory protection (Z88.2) 10, 12, 15.
3. Safe Handling and Storage Procedures: Provide clear guidelines for the safe handling and storage of chemicals and materials 1, 2, 4, 5, 6, 8, 9, 11, 15, 17. This includes precautions for preventing exposure (e.g., using in well-ventilated areas, avoiding contact with skin and eyes, not breathing vapors/mists/fumes) 1, 2, 4, 5, 6, 8, 9, 11, proper storage conditions (e.g., keeping containers tightly closed, storing at room temperature, keeping out of reach of children) 1, 2, 4, 5, 6, 9, 11, 12, 15, 17, and proper disposal methods in accordance with local, regional, national, and international regulations 1, 2, 4, 5, 6, 8, 9, 11.
4. Exposure Control Measures: Include engineering controls such as adequate ventilation to keep airborne levels of dust, fume, vapor, etc., below recommended exposure limits 2, 3, 4, 5, 6, 9, 10, 12, 15. List the Occupational Exposure Limits (OSHA-PEL and ACGIH-TLV) for chemicals used in the workplace 2, 3, 4, 5, 6, 9, 10, 12, 15.
5. Emergency Procedures: Detail procedures for accidental releases, including personal precautions, protective equipment, and methods for containment and cleaning up 1, 2, 4, 5, 6, 8, 9, 11. Also, include first-aid measures for different routes of exposure (eye contact, skin contact, inhalation, ingestion) 13, 18, 19 and specify the need for immediate medical attention when necessary .
6. Hygiene Practices: Emphasize the importance of good industrial hygiene practices, such as laundering contaminated clothing, washing hands before eating, drinking, or smoking, and avoiding eating, smoking, or drinking where materials are handled 1, 2, 4, 5, 6, 8, 9, 11, 12, 15, 17.
7. Fire Safety: Include information on flammability of materials, suitable and unsuitable extinguishing media, specific hazards arising from chemicals during a fire, and special protective equipment and precautions for firefighters 1, 8, 11, 13.
8. Hazard Identification: Ensure the manual includes information on potential health hazards, such as skin and eye irritation, respiratory tract irritation, and potential carcinogenic effects 13, 14, 16, 20. Provide information on both acute and chronic health hazards 14, 20.
9. Training: Training programs should cover hazard communication, proper use of PPE, safe handling and storage practices, emergency procedures, and general safety practices. Document all training sessions.
10. Regular Inspections: Implement a schedule for regular safety inspections to identify and correct potential hazards. Document all inspections and corrective actions.

By including these components, your safety manual will be more comprehensive and better aligned with OSHA requirements.