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Safety Manual | ZALEMO Corporation
ZALEMO Corporation — Safety Manual

Custom Safety
Manuals Built for
the Real Job Site

Clear, OSHA-compliant safety manuals tailored to your company's policies — from construction crews in the Midwest to industrial teams on the West Coast.

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21 Standard Sections
Company-Specific & Customized
Nationwide Experience
Audit & Onboarding Ready
Culture of Safety & Accountability
OSHA Compliant
Fully Customized
Nationwide Experience
Audit-Ready
21 Policy Sections

More Than Paperwork —
A Daily Safety Reference

A ZALEMO Safety Manual is a clear, customized document built to outline your company's health and safety policies, procedures, and expectations. We've created manuals for organizations nationwide — from construction crews in the Midwest to industrial teams on the West Coast — tailored to meet OSHA standards and real-world job site needs.

It provides employees with clear guidance on how to work safely, comply with legal requirements, and respond to risks. Whether you're preparing for audits, onboarding new hires, or building a safety-first culture, ZALEMO turns complex regulations into practical guidance your team will actually use.

Standards
OSHA & Real-World Job Site Needs
Approach
Built Around Your Specific Policies
Reach
Organizations Nationwide
Sections
21 Standards & Procedures Included

See Inside a ZALEMO Safety Manual

All 21 sections — navigate every policy and procedure. Use the tabs to jump directly to any section, or use the arrows to read through from start to finish.

Safety
Manual
Standards & Procedures
Eff. Oct 5, 2023  ·  Your Company
21
Policy Sections
Welcome to Your Safety Manual
Prepared by ZALEMO Corporation  ·  Effective October 5, 2023

This manual has been prepared specifically for your company and reflects your operations, your industry, and your workforce. It contains 21 Standards & Procedures — every policy your team needs to stay safe, compliant, and audit-ready.

Every section has been written in plain language and reviewed for compliance with applicable OSHA standards so your team can understand and apply it — not just file it away.

"This document is not valid unless authorized by the Department Manager. Any questions or clarifications are to be addressed to the Department Manager or Safety Representative."

How to Use This Manual
  • Supervisors must review the full manual before conducting employee safety orientations
  • New hires must read, understand, and sign the Employee Acknowledgement Form (§1) before beginning work
  • Post emergency procedures (§7) at all entrances and primary work stations
  • Review and update annually or whenever operations or regulations change
  • All updates must be logged in the Revision Table and re-authorized by Department Manager

Use the tabs above to jump to any section, or the arrows below to read through from start to finish. Left/right arrow keys also navigate the manual.

Table of Contents
Standards & Procedures  ·  21 Sections  ·  Effective Oct. 5, 2023
01
Employee Acknowledgement FormSigned receipt and acknowledgment of safety manual
02
Access to Employee Exposure & Medical RecordsOSHA 29 CFR 1910.1020 · employee rights and record access
03
Assured Equipment Grounding (GFCI)Ground fault protection · inspection requirements
04
Bloodborne PathogensOSHA 29 CFR 1910.1030 · exposure control plan
05
Drug & Alcohol — Non DOTTesting policy · prohibited conduct · consequences
06
Drug & Alcohol Policy StatementCompany commitment to a drug-free workplace
07
Emergency Action PlanEvacuation · emergency contacts · incident escalation
08
Fire Protection — ExtinguishersFire classes · PASS technique · inspection schedule
09
First AidKit requirements · first responder procedures · AED
10
General HousekeepingWorkplace cleanliness · storage · waste disposal
11
Health and Safety Policy StatementCompany commitment · objectives · accountability
12
Incident Investigation and ReportingNear-miss reporting · root cause analysis · OSHA reporting
13
Injury Illness RecordkeepingOSHA 300 / 300A / 301 log requirements
14
Management Policy StatementLeadership commitment · resources · accountability structure
15
Manual LiftingSafe lift technique · team lifts · ergonomic requirements
16
Pandemic PreparednessResponse plan · workplace modifications · communication
17
Risk Assessment — Identification of HazardsJSA process · hierarchy of controls · risk matrix
18
Safety Orientation ChecklistNew hire safety orientation · required sign-off items
19
Safety Responsibilities Policy StatementIndividual · supervisor · management obligations
20
Slips, Trips, and FallsPrevention · wet surface procedures · ladder safety
21
Stop Work AuthorityRight and obligation to stop unsafe work · no retaliation
01
Employee Acknowledgement Form

(Company Name)

Safety Manual  ·  Employee Acknowledgment

By my signature below, I acknowledge that I have received and will read the policies. I have been given the opportunity to ask questions, and have received clarification, and understand the contents.

This form must be completed and returned to the Department Manager before the employee begins any work. A copy is retained in the employee's personnel file.

Date
Employee Signature
Print Name

This document is uncontrolled when printed.

02
Access to Employee Exposure & Medical Records
1. Purpose

The Company has established a program compliant with OSHA 29 CFR 1910.1020 to provide employees access to their exposure and medical records.

2. Applicability

This policy applies to all employees, subcontractors, and visitors. An employee is considered "on the job" when on any company or client property — including parking areas — or on company time even if off premises.

3. Key Definitions
  • Access — The right and opportunity to examine and copy records
  • Employee Exposure Records — Environmental monitoring, biological monitoring, and material safety data sheets for toxic substances
  • Employee Medical Records — Health status records maintained by a physician, nurse, or health care personnel
  • Designated Representative — Any individual or organization given written authorization to exercise a right of access on behalf of the employee
  • Specific Written Consent — Written authorization containing employee name, date, releasing and receiving parties, scope, purpose, and expiration date
4. Employee Rights
  • Employees must be provided access to their records within 15 working days of request
  • Records must be retained for the duration of employment plus 30 years
  • Employees must be informed of the existence, location, and availability of records upon hire and annually
03
Assured Equipment Grounding (GFCI)

Ground Fault Circuit Interrupters (GFCIs) are required on all temporary power circuits at construction and general industry sites to prevent electrical shock from ground faults.

GFCI Requirements
  • All 120V, single-phase, 15- and 20-amp receptacles used in construction areas must be GFCI-protected
  • GFCI devices must be tested before each use with the built-in test/reset buttons
  • Any GFCI that fails testing must be immediately removed from service and replaced
  • Extension cords used outdoors or in wet/damp locations must be rated for that use
Assured Equipment Grounding Program (Alternative)
  • All equipment must be visually inspected before each use for damage, exposed wiring, or improper grounding
  • Each cord, plug, and tool must be tested at least every 3 months and after any incident of damage
  • Defective equipment must be removed from service immediately and tagged out-of-service
  • A written log of all inspections and tests must be maintained

Failure to use GFCI protection where required is a serious OSHA violation. Never bypass or defeat GFCI devices for any reason.

04
Bloodborne Pathogens

All blood and other potentially infectious materials (OPIM) must be treated as if infectious, regardless of the apparent health of the source individual.

Exposure Control Plan
  • An Exposure Control Plan must be maintained and updated annually, or when tasks/procedures change
  • The plan must identify job classifications and specific tasks with potential occupational exposure
  • All at-risk employees must receive training annually and upon initial assignment
Required PPE for Exposure Tasks
Disposable gloves (nitrile or latex) — all contact with blood/OPIM
Face shield or splash goggles — risk of splashing or spraying
Fluid-resistant gown — when clothing contamination is possible
Mouthpiece or resuscitation device — when performing CPR
Post-Exposure Procedures
  • Wash exposed skin immediately with soap and water; flush mucous membranes with water
  • Report the exposure to a supervisor immediately and complete an incident report
  • Seek medical evaluation within 2 hours — document source if known
  • Hepatitis B vaccination is made available to all at-risk employees at no cost
05
Drug & Alcohol — Non DOT

The Company is committed to a drug- and alcohol-free workplace. The use, possession, sale, or distribution of controlled substances or alcohol on company property or while on company time is strictly prohibited.

Prohibited Conduct
  • Reporting to work under the influence of alcohol, drugs, or any impairing substance
  • Using, possessing, selling, or distributing controlled substances on company property
  • Testing positive on any company-required drug or alcohol test
  • Refusing a required drug or alcohol test (treated as a positive result)
Testing Circumstances
Pre-Employment

Required before hire. Conditional offer of employment is withdrawn upon positive result.

Reasonable Suspicion

Supervisor observes signs of impairment. Two supervisors must document observations.

Post-Incident

Required after any workplace injury, near-miss, or property damage incident.

Return-to-Duty

Required following a substance abuse violation before employee returns to work.

06
Drug & Alcohol Policy Statement

It is the policy of (Company Name) to maintain a workplace free from the influence of drugs and alcohol. The Company recognizes that substance abuse is a health problem and is committed to helping employees address it.

Company Commitments
  • Maintain a safe, healthy, and productive work environment for all employees
  • Enforce this policy consistently and without favoritism at all levels of the organization
  • Provide access to Employee Assistance Program (EAP) resources for employees seeking help
  • Treat substance abuse violations as a serious safety matter, not solely a disciplinary one

Employees who voluntarily seek assistance for substance abuse issues prior to testing positive — and before disciplinary action is initiated — will not be subject to termination solely for seeking help, subject to continued compliance with treatment and this policy.

Employee Responsibilities
  • Report to work fit for duty — free from impairment at all times
  • Notify supervisor if prescribed medication may affect work performance or safety
  • Report coworkers suspected of impairment to a supervisor immediately
07
Emergency Action Plan

An Emergency Action Plan must be in place for all workplaces. All employees must be trained on evacuation routes, assembly points, and emergency contacts before beginning work.

Evacuation Procedure
  • Upon alarm or emergency announcement — stop work immediately and secure equipment if safe
  • Proceed to the nearest designated exit using marked evacuation routes
  • Do not use elevators. Do not re-enter for personal belongings
  • Assemble at the designated muster point and await supervisor accountability count
  • Do not re-enter until cleared by emergency services and management
Emergency Types & Response
Fire

Activate nearest pull station. Call 911. Evacuate. Do not attempt to fight unless trained and the fire is contained.

Medical Emergency

Call 911 immediately. Do not move the injured unless in immediate danger. Provide first aid only if trained.

Chemical Spill

Evacuate the area. Alert supervisor. Do not attempt cleanup without proper training and PPE.

Severe Weather

Move to the designated shelter area — interior room, lowest floor. Stay away from windows and doors.

08
Fire Protection — Extinguishers
Fire Extinguisher Classes
Class A Ordinary combustibles — wood, paper, cloth, plastic
Class B Flammable liquids and gases — grease, gasoline, oil, solvents
Class C Energized electrical equipment — use only non-conductive agents
Class D/K Combustible metals / cooking oils — specialized extinguishers required
PASS Technique
  • Pull — Pull the safety pin from the handle
  • Aim — Aim the nozzle at the base of the fire, not the flames
  • Squeeze — Squeeze the handle to discharge the agent
  • Sweep — Sweep side to side at the base of the fire until extinguished
Inspection & Maintenance
  • Monthly visual inspection required — check gauge, seal, nozzle, and physical condition
  • Annual professional inspection and service required (tagged and dated)
  • Placement: maximum 75-foot travel distance for Class A; 50 feet for Class B/C
  • Never block or obstruct access to fire extinguishers
09
First Aid

First aid supplies must be readily accessible at all times. At least one employee trained in first aid must be present or within 4 minutes of any worksite where medical facilities are not nearby.

Required First Aid Kit Contents (ANSI Z308.1)
Adhesive bandages (assorted sizes) — minimum 16 units
Sterile gauze pads and rolls
Antiseptic wipes and wound closure strips
Disposable gloves (minimum 2 pairs)
CPR breathing barrier / face shield
Emergency blanket and eye wash solution
First Aid Response
  • Call 911 for any injury requiring more than basic first aid
  • Do not move an injured person unless they are in immediate danger
  • All injuries requiring more than first aid must be reported to a supervisor immediately
  • AED (Automated External Defibrillator) locations must be posted and all personnel informed
  • First aid kits must be inspected monthly and restocked promptly after any use
10
General Housekeeping

A clean, organized workplace is fundamental to employee safety. Housekeeping is the responsibility of every employee — not just maintenance or janitorial staff.

Daily Requirements
  • All aisles and passageways must be kept clear — minimum 28-inch clearance at all times
  • Exit routes must never be blocked or obstructed for any reason
  • Spills must be cleaned up immediately and the area dried before work resumes
  • Scrap materials, waste, and debris must be removed from work areas regularly throughout the shift
  • All tools must be returned to their designated storage after use
Material Storage
  • Materials must be stored in a stable, secure manner — never stacked beyond safe height limits
  • Flammable/combustible materials must be stored away from ignition sources in approved containers
  • Chemicals must be stored according to their SDS requirements and properly labeled

Supervisors are responsible for ensuring housekeeping standards are maintained throughout their area. Regular inspections must be documented.

11
Health and Safety Policy Statement

It is the policy of (Company Name) to provide and maintain the highest attainable standards of safety and health for all employees. The prevention of occupationally-caused injuries and illnesses is of such consequence that it will be given priority over operating productivity when necessary.

Core Policy Commitments
  • Provide a workplace free from recognized hazards that are causing or are likely to cause serious injury
  • Comply fully with all applicable OSHA standards, regulations, and applicable legal requirements
  • Provide adequate training, equipment, and resources to enable employees to work safely
  • Encourage employees to actively participate in the safety program and report concerns without fear
  • Review safety performance regularly and update this policy to reflect operational changes

Every employee has the right and the obligation to stop work they believe to be unsafe. No employee will be disciplined for raising a genuine safety concern in good faith.

Annual Review

This policy shall be reviewed at least annually by senior management. Results of safety audits, incident rates, and employee feedback will be used to improve the safety program continuously.

12
Incident Investigation and Reporting

All incidents — including near-misses — must be reported immediately. Investigation is not about assigning blame; it is about identifying root causes and preventing recurrence.

OSHA Mandatory Reporting Timelines
8 Hours Any work-related fatality must be reported to OSHA
24 Hours Any work-related in-patient hospitalization, amputation, or loss of eye
Investigation Steps
  • Secure the scene — do not disturb physical evidence until the supervisor has assessed
  • Interview the injured party, all witnesses, and supervising personnel separately
  • Identify direct causes, contributing factors, and root causes using the 5-Why method
  • Develop corrective actions with assigned owners and implementation deadlines
  • Verify and document that corrective actions are completed and effective

Near-miss reporting is encouraged without penalty. A near-miss is a hazard identified before it causes harm — and is one of the most valuable safety improvement tools available.

13
Injury Illness Recordkeeping
Required OSHA Records
OSHA 300 Log

All recordable work-related injuries and illnesses must be entered within 7 calendar days of learning of the incident.

OSHA 301 Form

Individual incident report for each OSHA 300 entry. Must be completed within 7 days of the recordable incident.

OSHA 300A Summary

Annual summary must be posted in a visible location from February 1 through April 30 each year.

Record Retention

All OSHA 300, 300A, and 301 records must be retained for a minimum of 5 years.

Recordable vs. First Aid Only
  • Recordable: any work-related injury requiring medical treatment beyond first aid, restricted work, days away, loss of consciousness, or diagnosis of a significant injury
  • First Aid Only (not recordable): cleaning wounds, non-prescription medication at non-prescription strength, tetanus immunizations, simple bandaging

The 300A annual summary must be signed by a company executive and must remain posted even if zero incidents occurred during the year.

14
Management Policy Statement

The management of (Company Name) is committed to providing every employee with a safe and healthy workplace. This is not simply a legal obligation — it is a core organizational value that guides every decision we make.

Management Responsibilities
  • Allocate the resources, time, equipment, and personnel necessary to maintain a safe workplace
  • Lead by example — management must visibly comply with all safety policies and procedures
  • Ensure that all employees receive documented training appropriate to their role and hazard exposure
  • Investigate all incidents promptly and implement corrective actions without delay
  • Recognize and reinforce safe behavior — and hold employees accountable for unsafe behavior consistently

"Management accepts the responsibility for providing a safe workplace and will make every reasonable effort to correct identified hazards in a timely manner."

Accountability Structure

Safety responsibilities are defined at every level of the organization. Refer to §19 (Safety Responsibilities Policy Statement) for the full breakdown of individual, supervisory, and management obligations.

15
Manual Lifting

Manual material handling is one of the leading causes of workplace injury. Use proper technique every time, and request assistance or mechanical aids for loads that exceed safe limits.

Safe Lifting Technique
  • Assess the load before lifting — test the weight, check for sharp edges, verify grip points
  • Position your feet shoulder-width apart, close to the load, with one foot slightly forward
  • Bend at the knees — not the waist — and keep your back straight and chest forward
  • Grip the load firmly and keep it as close to your body as possible throughout the lift
  • Lift by straightening your legs — not by pulling with your back
  • Never twist while lifting or carrying — pivot with your feet instead
Team Lift Requirements
Required Any load exceeding 50 lbs — two-person minimum team lift required
Recommended Loads 35–50 lbs — evaluate load and conditions; team lift preferred
Solo OK Loads under 35 lbs — use proper technique; assess before lifting

Use mechanical aids (dollies, hand trucks, hoists) whenever available. No employee should strain to lift a load that a tool was designed to handle.

16
Pandemic Preparedness

The Company will follow guidance from the CDC, OSHA, and applicable public health authorities in the event of a declared pandemic or public health emergency. This plan is activated at management's discretion based on the severity and scope of the event.

Key Response Measures
  • A designated Pandemic Response Coordinator will be identified to lead internal response efforts
  • All employees must report symptoms of illness to their supervisor before reporting to work
  • Employees who are ill or symptomatic must not report to work until cleared by a medical professional
  • Physical distancing, enhanced cleaning, and PPE requirements will be implemented as directed by authorities
  • Remote work options will be provided where the nature of the work allows
Communication Plan
  • All pandemic-related policy updates will be communicated promptly to all employees in writing
  • Employees will be directed to verified public health resources (CDC, OSHA, state health departments) for guidance
  • Business continuity planning will be reviewed and updated as conditions evolve
17
Risk Assessment — Identification of Hazards

Risk assessment must be performed before all new tasks, in response to changes in operations, and whenever a near-miss or incident indicates an uncontrolled hazard. All employees participate in identifying hazards in their work area.

Hierarchy of Controls
1st Elimination — physically remove the hazard from the workplace
2nd Substitution — replace the hazard with something less dangerous
3rd Engineering Controls — isolate people from the hazard (guards, ventilation, interlocks)
4th Administrative Controls — change how people work (procedures, training, scheduling)
5th PPE — protect the worker with personal protective equipment (last resort)
Job Safety Analysis (JSA)
  • Break the job into steps and identify hazards associated with each step
  • Assign a risk level to each hazard using the likelihood × severity matrix
  • Select and document controls from the hierarchy above for each identified hazard
  • Review the JSA with all workers before beginning the task and update when conditions change
18
Safety Orientation Checklist

All items below must be reviewed with each new employee and contractor before beginning work. The supervisor must initial each completed item and have the employee sign the completed checklist.

Emergency evacuation routes, exits, and designated muster/assembly point
Location of first aid kits, AED, and eyewash/emergency shower stations
Fire extinguisher locations and PASS technique demonstrated
Incident and near-miss reporting procedure
PPE requirements for this workplace and job-specific tasks
Hazard Communication (HazCom) program and SDS binder location
Drug and alcohol policy — tested, no-use requirements, and consequences
Stop Work Authority — right and obligation to stop unsafe work
Job-specific safety training for assigned tasks and equipment
Employee Acknowledgement Form (§1) — signed and returned

Completed orientation checklists must be retained in the employee personnel file. Orientation must be documented before the employee begins any work activities.

19
Safety Responsibilities Policy Statement
All Employees Must
  • Report to work fit for duty — free from impairment by any substance
  • Wear required PPE for the task and zone at all times
  • Immediately report any injury, near-miss, or unsafe condition to a supervisor
  • Follow all established safety procedures, rules, and permit requirements
  • Never operate equipment for which they have not been trained and authorized
  • Participate in all required safety training and orientations
Supervisors Are Responsible For
  • Conducting pre-shift safety briefings and verifying PPE compliance before work begins
  • Ensuring all new employees complete orientation (§18) before starting
  • Documenting incidents, near-misses, and corrective actions in writing
  • Enforcing safety rules consistently and without exception at all times

Any employee has the right to refuse work they believe to be imminently unsafe — without penalty or retaliation. Concerns must be reported to a supervisor or safety representative immediately and documented.

20
Slips, Trips, and Falls

Slips, trips, and falls are the leading cause of workplace injuries. Most are preventable through basic housekeeping, proper footwear, and awareness.

Prevention Requirements
  • Walking surfaces must be kept clean, dry, and free of clutter at all times (see §10 Housekeeping)
  • Employees must wear slip-resistant footwear appropriate for the work environment
  • Wet or slippery surfaces must be posted with warning signs and cleaned immediately
  • Adequate lighting must be maintained in all work areas, walkways, and stairways
Fall from Elevation Protection
4 ft+ General Industry — fall protection required (OSHA 29 CFR 1910.23)
6 ft+ Construction — fall protection required (OSHA 29 CFR 1926.502)
Ladder Safety
  • Inspect all ladders before each use — remove any defective ladder from service immediately
  • Maintain three points of contact when ascending or descending at all times
  • Never stand on the top two rungs of a stepladder
  • Extension ladders must extend 3 feet above the landing point and be secured at the top
21
Stop Work Authority

Every employee — at every level — has both the right and the obligation to stop work when they believe it poses an imminent threat to the safety of any person. This authority is non-negotiable and cannot be overridden by schedule, productivity, or cost pressure.

No employee will be disciplined, penalized, or retaliated against in any way for exercising Stop Work Authority in good faith. Fear of consequences must never prevent a worker from stopping unsafe work.

Stop Work Process — S.N.I.C.R.
  • STOP — Immediately halt the work activity posing the hazard
  • NOTIFY — Alert the supervisor and all affected personnel of the hazard and the stop work action
  • INVESTIGATE — Assess the hazard — do not resume work until the concern is fully understood
  • CORRECT — Implement appropriate controls from the hierarchy of controls (see §17)
  • RESUME — Return to work only after the hazard is corrected and supervisor authorizes resumption
Documentation

All Stop Work Authority events must be documented using the Hazard Identification / Near-Miss Report Form and submitted to the Safety Manager within 24 hours. Patterns in stop work events should be reviewed in safety meetings to drive systemic improvement.

21 Sections. Every Policy Your Team Needs.

Each ZALEMO Safety Manual is built around your company's operations and industry — structured to cover every critical compliance area, from first-day orientation through ongoing incident management.

Policies & Statements

Health & Safety Policy, Management Policy, Safety Responsibilities, and Drug & Alcohol Policy Statement — all customized to your company and signed by leadership.

§§ 6, 11, 14, 19

Employee Acknowledgement & Orientation

Signed acknowledgment form and a complete Safety Orientation Checklist covering every required topic before an employee begins any work activity.

§§ 1, 18

Hazard ID & Risk Assessment

JSA process, hierarchy of controls, risk matrix, general housekeeping standards, and slips/trips/falls prevention — built for your specific site conditions.

§§ 10, 17, 20

Emergency Preparedness

Emergency Action Plan, Fire Protection & Extinguishers, First Aid requirements, and Pandemic Preparedness — structured for rapid employee reference.

§§ 7, 8, 9, 16

Health & Exposure Protection

Access to Medical Records, Bloodborne Pathogens exposure control, GFCI/electrical grounding, Manual Lifting ergonomics, and Drug & Alcohol testing procedures.

§§ 2, 3, 4, 5, 15

Incident Response & Recordkeeping

Incident Investigation & Reporting, OSHA 300/300A/301 Injury Recordkeeping, and Stop Work Authority — the full compliance and accountability backbone.

§§ 12, 13, 21

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Tell us about your company, your industry, and your workforce — ZALEMO will build a manual that fits.

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