SpaceX Starbase Injury Rates Higher Than Industry Rivals
▼ Summary
– SpaceX’s Starbase facility has the highest injury rate among its sites, with rates nearly six times the industry average for space vehicle manufacturing in 2024.
– Starbase’s Total Recordable Incident Rate (TRIR) was 4.27 injuries per 100 workers in 2024, far exceeding industry peers like Blue Origin and ULA.
– OSHA data shows Starbase’s injury rates have remained high since 2019, despite overall industry safety improvements over the past 30 years.
– NASA has a $4 billion stake in Starship for lunar missions but states high TRIR alone doesn’t trigger contract breaches unless major safety violations occur.
– Former OSHA officials and data suggest Starbase’s injury rates indicate serious safety concerns, including past incidents like amputations and a crane collapse.
SpaceX’s Starbase facility in Texas reports worker injury rates significantly higher than industry competitors, raising concerns about workplace safety amid the company’s ambitious Starship development program. Recent data from the Occupational Safety and Health Administration reveals Starbase’s injury rate reached 4.27 incidents per 100 workers in 2024, nearly six times the average for space vehicle manufacturing and three times the broader aerospace sector’s rate.
The sprawling Texas site, now incorporated as its own city, serves as the primary hub for SpaceX’s Starship program. This next-generation rocket system aims to revolutionize space travel with full reusability and heavy-lift capabilities. However, the push for rapid innovation appears to coincide with elevated safety risks. Since 2019, Starbase has consistently reported injury rates far exceeding both SpaceX’s other facilities and industry norms.
OSHA’s Total Recordable Incident Rate (TRIR) metric shows Starbase workers experienced 3,558 restricted-duty days and 656 lost-time days in 2024 alone. While these figures represent an improvement from 2023’s peak of 5.9 injuries per 100 workers, they remain alarmingly high compared to historical benchmarks. The broader space manufacturing sector has seen injury rates plummet from 4.2 to 0.7 per 100 workers since 1994, making Starbase’s current numbers resemble outdated safety standards.
SpaceX’s other manufacturing sites report lower but still concerning TRIR figures:
- McGregor, Texas (engine testing): 2.48
- Bastrop, Texas (Starlink production): 3.49
- Hawthorne, California (Falcon rockets): 1.43
- Redmond, Washington (satellites): 2.89
Safety experts emphasize these patterns warrant investigation. Debbie Berkowitz, former OSHA Chief of Staff, described Starbase’s metrics as “a red flag” indicating systemic safety issues. Of 14 OSHA inspections at SpaceX facilities since 2021, six targeted Starbase incidents, including a crane collapse in 2025 and a partial finger amputation in 2021. Independent reports have documented additional unreported injuries, including crushed limbs and one fatality.
NASA, which relies on Starship for its Artemis lunar missions, maintains contractual provisions allowing intervention for major safety violations. However, high TRIR rates alone don’t trigger these clauses. The agency stated it works closely with commercial partners to foster safety cultures, though Starbase’s metrics continue to outpace competitors like United Launch Alliance (1.12 TRIR) and Blue Origin (1.09 TRIR).
While debate persists about TRIR’s effectiveness as a safety metric, the consistent disparity between Starbase and industry peers suggests operational pressures may compromise worker protection. As SpaceX accelerates Starship testing, with nine integrated flights attempted since April 2023, the balance between innovation and employee welfare remains under scrutiny.
(Source: TechCrunch)
