SpaceX’s Starbase manufacturing facility in Texas has been under scrutiny for its high injury rates compared to other aerospace manufacturing outfits. According to safety records reviewed by JS, Starbase has injury rates almost six times higher than the industry average for space vehicle manufacturing and nearly three times higher than the aerospace manufacturing sector as a whole.
The facility is home to SpaceX’s ambitious Starship program, a fully reusable, ultra-heavy-lift rocket designed to launch satellites and other payloads into space. Since the first orbital test of Starship in April 2023, SpaceX has conducted several integrated flights, including successful attempts at catching the Super Heavy booster with innovative “chopstick” arms attached to the launch tower.
Despite the rapid progress at Starbase, the high injury rates raise concerns about the safety culture at SpaceX. The Total Recordable Incident Rate (TRIR) at Starbase reached 4.27 injuries per 100 workers in 2024, significantly higher than industry averages. The data also reveals that injured employees at Starbase were unable to perform their normal job duties for a total of 3,558 restricted-duty days and 656 lost-time days.
While OSHA uses TRIR to measure safety records, some safety professionals question its reliability in predicting serious incidents like fatalities. Starbase’s TRIR is considered a red flag for serious safety issues that need to be addressed, with several accidents and injuries reported at the facility over the past years, including a partial finger amputation and a crane collapse.
NASA, a major stakeholder in Starship’s development, has contracts with SpaceX for lunar missions and crewed flights to the International Space Station. The agency closely monitors safety measures at SpaceX, with clauses in the contracts allowing action in case of safety breaches. However, a high TRIR alone may not trigger immediate action from NASA.
In comparison to other rocket manufacturers, Starbase still leads in injury rates, with ULA’s facility in Decatur, Alabama, and Blue Origin’s rocket park in Florida reporting lower TRIR rates. The data highlights the need for improved safety measures at SpaceX’s Starbase facility to ensure the well-being of its employees and the success of its ambitious space exploration projects.
