Published on: May 19, 2026
Safeguarding Advanced Manufacturing Infrastructure
Hazard: Maintenance technicians at the sprawling Starlink User Terminal and Advanced Packaging facility faced serious leading-edge fall exposures while servicing roof drains and navigating abrupt elevation changes across multiple roof sections.
Solution: An engineered safety footprint combining 1,100 linear feet of active Kee Line cable lifelines and four custom Kee Crossover platforms bolted to the facility parapets.
Benefits: Achieved 100% OSHA and ANSI compliance, eliminated elevation-transition fall hazards without breaching the six-foot leading-edge threshold, and provided secure two-user tie-off points without compromising the structural integrity of the roof deck.
The Challenge: Complex Geometry and Stringent Standards
SpaceX’s high-volume Starlink manufacturing center spans substantial square footage with varying roof tiers. Facility maintenance crews required recurring access to leading edges to clear drainage systems and inspect rooftop equipment. Without dedicated infrastructure, personnel were forced to negotiate severe roof elevation drops and work near open edges, creating substantial fall risks. The challenge required designing a dual-action safety system that integrated active fall arrest with passive safe-access pathways, all while coordinating around tight new-construction timelines and strict industrial parameters.
The Process: Collaborative Engineering and Trade Alignment
FLS safety specialists partnered with SpaceX stakeholders to identify exact operational requirements across the site. In July 2025, FLS engineering conducted comprehensive site audits to verify roof dimensions, evaluate structural substrates, and coordinate penetrations alongside the roofing contractor, Parsons Roofing.
To accommodate active facility build-out schedules, FLS developed complete engineering submittals detailing structural anchorage points and custom-fit platform configurations. The engineering team calibrated the system to integrate seamlessly with the existing concrete wall transitions and steel decking, adapting installation sequences to deliver zero-downtime execution.
The Solution: Multi-System Fall Abatement Footprint
FLS engineered, fabricated, and installed a turnkey fall protection package tailored to the facility’s complex roof layout:
- Kee Line Rooftop Cable Systems: 1,100 linear feet of continuous, active cable lifelines anchored securely to the decking via toggle-bolt connections, engineered to support up to two users in fall arrest simultaneously.
- Custom Kee Crossover Platforms: Four heavy-duty, modular crossover structures securely bolted to concrete dividing walls, enabling maintenance staff to traverse elevation tiers without exposure to drop-offs.
- Leading-Edge Cantilever Access: One crossover platform was custom-engineered to extend directly over a perimeter wall, allowing personnel to safely access critical points without stepping past the unprotected six-foot threshold.
- Full Decking and Waterproofing Coordination: FLS executed all necessary roof penetrations in coordination with site roofing partners to guarantee ongoing building envelope integrity.
Summary: Long-Term Aerospace Safety Partnership
By combining passive crossover walkways with continuous active cable arrest lines, FLS delivered an integrated safety ecosystem that protects personnel from life-threatening falls while streamlining daily facility operations. The turnkey deployment fully abates compliance liabilities and equips the Bastrop manufacturing hub with durable, certified fall protection.
To preserve long-term compliance and structural integrity, the facility’s active and passive fall protection assets are enrolled in the FLS lifecycle inspection and recertification schedule.
Ready to enhance safety and efficiency at your facility? Contact Flexible Lifeline Systems for a comprehensive safety audit and let our team of experts help you find the perfect solution for your work at height.
