OSHA Investigates SpaceX Starbase Crane Accident

SpaceX Starbase Site Incident Under OSHA Investigation

An incident occurred in November at SpaceX’s Starbase location where a construction worker was seriously injured. The worker sustained crushing injuries after being struck by a substantial metal support that detached from a crane during wall construction.

Eduardo Cavazos, the worker involved, initiated a lawsuit in November, detailing the circumstances of the accident. The legal action is directed against both SpaceX and a contracting company, alleging negligence contributed to the incident.

OSHA’s Response and Investigation

SpaceX promptly reported the event to the Occupational Safety and Health Administration (OSHA). Following the report, OSHA initiated a “rapid response investigation” into the matter, as confirmed by Joanna Hawkins, deputy regional director of public affairs.

Typically, a rapid response investigation commences with OSHA requesting additional information from the employer. This is done to assess the need for an on-site inspection. Currently, OSHA is awaiting a response from SpaceX to their initial inquiry.

Previous Crane Incident at Starbase

This marks the second crane-related accident at the Starbase facility this year that is currently under OSHA scrutiny. An investigation was also launched in late June concerning a crane collapse at the same location.

The extent of any injuries resulting from the June crane collapse remains unknown. Neither SpaceX nor local city officials have released statements regarding the incident, which was documented by livestream footage from LabPadre.

Growing Safety Concerns at Starbase

These crane accidents are indicative of a broader pattern of incidents occurring at the rapidly developing launch complex in South Texas. This increased activity is linked to CEO Elon Musk’s ambitious goals for the development of large-scale rockets designed for lunar and Martian travel.

The facility’s expansion and the accelerated development schedule appear to be contributing factors to the rising number of reported incidents.

Injuries Sustained: Hip, Knee, and Tibia Fracture

Legal representatives for Cavazos, a Cameron County, Texas resident, initiated a lawsuit in November, shortly following the incident. The claim asserts he was employed as a subcontractor for CCC Group, engaged by SpaceX for the construction of concrete barriers at the Starbase facility.

According to the lawsuit, on November 15th, a crane operator was in the process of raising a “vertical formwork” – a structure used to contain wet concrete during the curing process – when a metal support component became dislodged and fell onto Cavazos.

An updated petition filed recently alleges that another CCC Group employee was operating the crane and was observed utilizing a cell phone in proximity to the time of the accident. The crane operator reportedly lowered the formwork in a negligent manner, resulting in its impact with the ground and startling Cavazos alongside two colleagues.

Subsequently, the formwork was rapidly elevated, and it was during this action that a 1,200-pound support beam struck Cavazos, as detailed in the legal complaint.

The impact from the metal support caused fractures to Cavazos’ hip, knee, and tibia. He also experienced additional injuries affecting his neck, head, shoulders, back, and legs.

His legal team states, “It is highly probable that [Cavazos] requires and/or will require physical rehabilitation, ongoing medication, pain management therapies, and/or surgical procedures to mitigate the pain resulting from the injuries sustained in this event.”

Cavazos is pursuing legal action against both CCC Group and SpaceX, citing negligence, and is requesting unspecified financial compensation. The lawsuit contends that both companies bear responsibility for failing to confirm the secure attachment of the metal support and for not adequately alerting workers to potential hazards present at the worksite.

Requests for statements from representatives of CCC Group and SpaceX went unanswered. Cavazos’ attorneys have chosen not to provide any commentary beyond the information contained within the filed complaint.

Safety Concerns at SpaceX’s Starbase Facility

For several years, the SpaceX Starbase facility has been the site of serious worker injuries. A 2023 Reuters investigation brought to light numerous previously undisclosed incidents, including a fatality that occurred during the initial construction phase in 2014 in South Texas.

Available public records indicate that the site continues to present a higher level of risk compared to other SpaceX locations and facilities operated by competitor companies.

Incident Rate Analysis

An analysis of Occupational Safety and Health Administration (OSHA) data conducted by TechCrunch in July revealed a Total Recordable Incident Rate (TRIR) of approximately 4.27 injuries for every 100 workers at Starbase in 2024.

For comparison, SpaceX’s rocket testing facility in McGregor, Texas, reported a TRIR of 2.48 in 2024. The Hawthorne, California site had a TRIR of 1.43. The average TRIR for the aerospace manufacturing industry in 2024 was 1.6 injuries per 100 workers.

Debbie Berkowitz, a former OSHA chief of staff, stated to TechCrunch that Starbase’s TRIR “signals a critical safety concern requiring immediate attention.”

Reporting and Transparency Issues

Maintaining transparency at Starbase proves challenging. Regulations require companies to report severe injuries to OSHA within 24 hours if they result in hospitalization, amputation, or loss of an eye.

While SpaceX seemingly complied with this requirement in the case involving Cavazos, OSHA issued a $7,000 penalty in early June for failing to report a separate qualifying injury at Starbase. SpaceX disputed the penalty, ultimately reaching a confidential settlement with OSHA.

Expansion Plans and Increasing Pressure

SpaceX has been developing Starbase for over a decade, and substantial expansion plans are underway. Currently, the company is constructing “Gigabay,” a $250 million, 700,000-square-foot rocket factory anticipated to be completed by the end of 2026.

This facility is projected to have the capacity to produce up to 1,000 Starship rockets annually.

Furthermore, SpaceX is facing mounting pressure. Sean Duffy, the acting NASA administrator, recently criticized the company for delays in resuming lunar missions, particularly following Elon Musk’s description of such missions as a diversion from Mars exploration.

Duffy indicated that NASA might consider utilizing rockets from Blue Origin, Jeff Bezos’ space company, to achieve a lunar landing before China, which aims to accomplish this feat by 2029.

This article has been updated to reflect new details from Cavazos’ revised petition.