TRIR at Starbase remains nearly six times higher than industry peers, raising concerns ahead of NASA lunar missions
A High Price for Rapid Progress
SpaceX’s Starbase facility in Texas, home to its ambitious Starship rocket program, is grappling with workplace injury rates far above aerospace industry norms. According to OSHA data reviewed by TechCrunch, Starbase recorded 4.27 injuries per 100 workers in 2024 — nearly six times higher than the sector average of 0.7.
- Industry Context: The space vehicle manufacturing sector has improved its safety metrics dramatically since the 1990s, but Starbase’s injury rate reflects a return to 30-year-old safety levels.
- Company Comparison: While all of SpaceX’s factories exceed the industry average, Starbase remains the most dangerous, followed by booster recovery operations (TRIR: 7.6).
Injury Metrics and Safety Culture
The Total Recordable Incident Rate (TRIR) is OSHA’s standard for comparing workplace injuries. Starbase’s TRIR reflects a consistent pattern since 2019, with thousands of lost and restricted-duty days logged in 2024 alone:
- Restricted Duty Days: 3,558
- Lost-Time Days: 656
- Average Employees: 2,690
While TRIR does not differentiate between minor and severe injuries, experts say such persistent rates suggest structural safety issues. Former OSHA official Debbie Berkowitz called the numbers “a red flag.”
Examples and Incidents
TechCrunch’s review also found 14 OSHA inspections at SpaceX facilities in four years — six of them at Starbase. Notable incidents include:
- A partial finger amputation in 2021
- A crane collapse in June 2025 (inspection ongoing)
- Reports from other media outlets have uncovered crushed limbs and at least one fatality
Lagging Behind Rivals
Despite progress from 2023’s peak TRIR of 5.9, Starbase remains well above:
- United Launch Alliance (ULA): 1.12
- Blue Origin: 1.09
- Aerospace manufacturing average: 1.6
- Other SpaceX facilities (TRIRs in 2024):
- McGregor: 2.48
- Bastrop: 3.49
- Hawthorne: 1.43
- Redmond: 2.89
NASA Watching Closely
NASA is closely linked to Starbase’s future. Its $4+ billion contract with SpaceX for two crewed lunar landings on Starship includes safety clauses that could trigger reviews in the event of “willful” OSHA violations or fatalities.
While a high TRIR does not alone violate the contract, it puts pressure on both parties to monitor risks. NASA says it is “in regular contact” with SpaceX and continues to push for a “healthy safety culture.”
A Culture of Speed — at a Cost
Starbase’s mission to build the world’s most powerful reusable rocket has led to rapid-fire test launches and development milestones. Elon Musk’s aggressive pace — while fueling innovation — appears to correlate with persistently high injury levels.
Experts note the TRIR metric is debated, especially for smaller firms, but at Starbase’s scale and influence, the data is hard to ignore. The challenge now is whether SpaceX can balance ambition with accountability, especially as NASA’s moonshot plans hinge on Starship’s success.
