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At SpaceX, worker injuries soar in Elon Musk’s rush to Mars

Reuters documented at least 600 previously unreported workplace injuries at Musk’s rocket company: crushed limbs, amputations, electrocutions, head and eye wounds and one death. SpaceX employees say they’re paying the price for the billionaire’s push to colonize space at breakneck speed.

A REUTERS INVESTIGATION, By MARISA TAYLOR , Nov. 10, 2023,

One windy night at Elon Musk’s SpaceX facility in McGregor, Texas, Lonnie LeBlanc and his co-workers realized they had a problem.

They needed to transport foam insulation to the rocket company’s main hangar but had no straps to secure the cargo. LeBlanc, a relatively new employee, offered a solution to hold down the load: He sat on it.

After the truck drove away, a gust blew LeBlanc and the insulation off the trailer, slamming him headfirst into the pavement. LeBlanc, 38, had retired nine months earlier from the U.S. Marine Corps. He was pronounced dead from head trauma at the scene.

Federal inspectors with the U.S. Occupational Safety and Health Administration (OSHA) later determined that SpaceX had failed to protect LeBlanc from a clear hazard, noting the gravity and severity of the violation. LeBlanc’s co-workers told OSHA that SpaceX had no convenient access to tie-downs and no process or oversight for handling such loads. SpaceX acknowledged the problems, and the agency instructed the company to make seven specific safety improvements, including more training and equipment, according to the inspection report.

It was hardly the last serious accident at SpaceX. Since LeBlanc’s death in June 2014, which hasn’t been previously reported, Musk’s rocket company has disregarded worker-safety regulations and standard practices at its inherently dangerous rocket and satellite facilities nationwide, with workers paying a heavy price, a Reuters investigation found. Through interviews and government records, the news organization documented at least 600 injuries of SpaceX workers since 2014.

Many were serious or disabling. The records included reports of more than 100 workers suffering cuts or lacerations, 29 with broken bones or dislocations, 17 whose hands or fingers were “crushed,” and nine with head injuries, including one skull fracture, four concussions and one traumatic brain injury. The cases also included five burns, five electrocutions, eight accidents that led to amputations, 12 injuries involving multiple unspecified body parts, and seven workers with eye injuries. Others were relatively minor, including more than 170 reports of strains or sprains.

Current and former employees said such injuries reflect a chaotic workplace where often under-trained and overtired staff routinely skipped basic safety procedures as they raced to meet Musk’s aggressive deadlines for space missions. SpaceX, founded by Musk more than two decades ago, takes the stance that workers are responsible for protecting themselves, according to more than a dozen current and former employees, including a former senior executive.

Musk himself at times appeared cavalier about safety on visits to SpaceX sites: Four employees said he sometimes played with a novelty flamethrower and discouraged workers from wearing safety yellow because he dislikes bright colors.

The lax safety culture, more than a dozen current and former employees said, stems in part from Musk’s disdain for perceived bureaucracy and a belief inside SpaceX that it’s leading an urgent quest to create a refuge in space from a dying Earth.

“Elon’s concept that SpaceX is on this mission to go to Mars as fast as possible and save humanity permeates every part of the company,” said Tom Moline, a former SpaceX senior avionics engineer who was among a group of employees fired after raising workplace complaints. “The company justifies casting aside anything that could stand in the way of accomplishing that goal, including worker safety.”

One severe injury in January 2022 resulted from a series of safety failures that illustrate systemic problems at SpaceX, according to eight former SpaceX employees familiar with the accident. In that case, a part flew off during pressure testing of a Raptor V2 rocket engine – fracturing the skull of employee Francisco Cabada and putting him in a coma.

The sources told Reuters that senior managers at the Hawthorne, California site were repeatedly warned about the dangers of rushing the engine’s development, along with inadequate training of staff and testing of components. The part that failed and struck the worker had a flaw that was discovered, but not fixed, before the testing, two of the employees said……………………………………………………………………………………………………………………………………………

NASA said it has paid SpaceX $11.8 billion to date as a private space contractor. The agency did not comment on the company’s safety record but said it has the option of enforcing contract provisions that require SpaceX to “have a robust and effective safety program and culture.”……………………………………………………………………………………………………………………………………………………..

Shortcutting safety

On Jan. 18 of last year, part of a Raptor V2 engine broke away during pressure testing at the SpaceX facility in Hawthorne, California. The part, a fuel-controller assembly cover, careened into the head of Cabada, a SpaceX technician. Nearly two years later, the father of three young children remains in a coma with a hole in his skull, family members said.

The accident generated news last year but little has emerged until now about the causes. The incident stemmed from several safety lapses at the Hawthorne site, according to Reuters interviews with eight former SpaceX employees familiar with the incident and the testing preparations…………………………………………………………………………………………………………………………………….

SpaceX’s rejection of a more rigorous training program, its moves to limit testing, and the discovery of the cover’s defect before the accident haven’t been previously reported……………………………………………………………………………………………………………………………

Flamethrowers and safety yellow

Musk is well-known as a hands-on manager. He was directly involved in handing down sometimes unrealistic deadlines, said current and former employees. Musk’s heavy involvement in scheduling resulted in “significantly more unsafe working conditions than would have existed otherwise,” said Moline, the engineer.

One former SpaceX executive defended Musk, saying he would listen to employees who were willing to go “toe-to-toe” with him on safety issues and took them seriously.

Another former executive said Musk cared about his workers and was bothered when they got hurt, but that safety was not one of Musk’s priorities. Musk, the ex-manager said, thought that “workers take care of their safety themselves.”

This former executive said that top company officials knew its injury rates ran high but attributed the problem to employing a largely young workforce in a dangerous industry. SpaceX leaders also believed the company shouldn’t be held to the same standard as competitors because SpaceX oversees more missions and manufacturing, the two former executives said.

That attitude is a red flag that a company is rationalizing a fundamentally unsafe environment, according to four worker-safety experts interviewed by Reuters, including Barab, the former OSHA deputy assistant secretary.

“SpaceX shouldn’t be exempt from protecting workers from being injured or killed,” Barab said, “just because they’re doing innovative work.

A video posted widely online shows Elon Musk playing with a novelty flamethrower produced by his tunneling firm, the Boring Company.

Four SpaceX employees told Reuters they were disturbed by Musk’s habit of playing with a flamethrower when he visited the SpaceX site in Hawthorne. The device was marketed to the public in 2018 as a $500 novelty item by Musk’s tunnel-building firm, the Boring Company. Videos posted online show it can shoot a thick flame more than five feet long. Boring later renamed the device the “Not-A-Flamethrower” amid reports of confiscations by authorities.

For years, Musk and his deputies found it “hilarious” to wave the flamethrower around, firing it near other people and giggling “like they were in middle school,” one engineer said. Musk tweeted in 2018 that the flamethrower was “guaranteed to liven up any party!” At SpaceX, Musk played with the device in close-quarters office settings, said the engineer, who at one point feared Musk would set someone’s hair on fire……………………………………………………………………………………………..

A death and a $7,000 fine

SpaceX has faced few consequences from safety regulators for its failure to report annual safety data and to protect workers in incidents reviewed by federal and state inspectors, agency records show.

OSHA and CalOSHA have fined the billionaire’s rocket company a total of $50,836 for violations stemming from one worker’s death and seven serious safety incidents, regulatory records show.

OSHA did not comment on the modest penalties that resulted from inspections of SpaceX.

SpaceX’s history of injuries and regulatory run-ins in California underscores the limits of worker-safety regulation. Fines are capped by law and pose little deterrent for major companies, experts in U.S. worker safety regulation said. Federal and state regulators also suffer from chronic understaffing of inspectors, they said. OSHA did not address questions about staffing levels but said it “focuses its resources on hazardous workplaces.”……………………………………………………………………………………………………………..

Safety at SpaceX: How Reuters analyzed workplace injuries

Reuters documented at least 600 injuries at SpaceX through a variety of public records, including the company’s own injury logs at three facilities that were inspected by regulators…………………………………………………………………………………………………………………………………….. more https://www.reuters.com/investigates/special-report/spacex-musk-safety/—

November 12, 2023 - Posted by Christina Macpherson | safety, space travel