Safety KPIs
Shutdown Safety KPI Targets: TRIR, DART and Near Misses
TRIR is recordable cases times 200,000 divided by hours worked, the 200,000 representing 100 full-time workers for a year. DART uses only cases with days away, restriction or transfer. Do not invent a benchmark: compare with the US Bureau of Labor Statistics 2024 rate for your industry (private industry 2.3 recordable and 1.4 DART per 100 workers), then set a target against your own history.
How MaintWiz helps: The MaintWiz shutdown module carries this work as work packages with checklists, readings and photos, permits and readiness gates, so the result stays with the work order.
By Jai Balachandran · Technical review: Murali Nerur Pasupathy · Published · Last reviewed
What MaintWiz adds:Critical path and floatReadiness gatesPermits and isolationsChecklists with readings
Formulas
How are TRIR and DART calculated?
Both use the same base of 200,000 hours, which equals 100 full-time workers over a year.
| Measure | Formula | Worked example (illustration) | Basis |
|---|---|---|---|
| Total recordable incident rate (TRIR) | Recordable cases x 200,000 / hours worked | 7 x 200,000 / 400,000 = 3.5 | BLS |
| DART rate | (Days-away cases + restricted or transferred cases) x 200,000 / hours worked | 3 x 200,000 / 400,000 = 1.5 for three such cases | BLS, OSHA |
Only hours actually worked count; paid time not worked, such as holiday and sick leave, is excluded.
Industry rates
What are typical industry rates to compare with?
BLS 2024 rates per 100 full-time workers, released 22 January 2026; they are all-year, all-employer averages, not turnaround-specific.
| Industry (NAICS) | Total recordable cases | DART (days away, restriction or transfer) |
|---|---|---|
| Private industry | 2.3 | 1.4 |
| Manufacturing (31-33) | 2.7 | 1.7 |
| Chemical manufacturing (325) | 1.6 | 1.0 |
| Petroleum and coal products manufacturing (324) | 1.0 | 0.6 |
| Support activities for mining (213) | 0.9 | 0.7 |
| Utilities (22) | 1.9 | 1.2 |
| Construction (23) | 2.2 | 1.3 |
| Heavy and civil engineering construction (237) | 1.8 | 1.0 |
| Specialty trade contractors (238) | 2.3 | 1.4 |
| Primary metal manufacturing (331) | 3.3 | 2.0 |
| Paper manufacturing (322) | 2.4 | 1.6 |
Oil and gas extraction (211) is not published for 2024. No public source gives a turnaround-specific benchmark.
Targets
How should you set the target for a shutdown?
Use your own history first, then the industry rate, then leading indicators.
- Take the last shutdowns on the same site as the baseline, with the same counting rules and hours including contractors.
- Compare with the BLS rate for your industry and set a target that improves on both your history and the industry rate.
- Do not use a near-miss ratio as a target: Heinrich's 1:29:300 is questioned and Bird's studies gave other ratios. Set a minimum reporting expectation and track reports as a leading indicator.
- Add process safety indicators: the US Chemical Safety Board found BP relied on injury statistics while process safety performance declined, and UK HSE publishes HSG254 on leading and lagging indicators.
- Report permits issued with hazards and controls adequately specified as a leading indicator of permit quality.
FAQ
Frequently asked questions
How is TRIR calculated?
Recordable cases times 200,000 divided by hours worked. The 200,000 stands for 100 full-time workers for a year.
What does DART include?
Cases with days away from work, restricted work or job transfer, on the same 200,000 basis.
What is a good TRIR target for a shutdown?
No public source gives a universal target. Compare with the BLS rate for your industry, use your own recent shutdowns as the baseline and set a target that improves on both.
What should the near-miss ratio be?
There is no verified standard ratio. Track near-miss reports as a leading indicator of reporting culture and set a minimum reporting expectation instead of a ratio.
Are injury rates enough to judge shutdown safety?
No. The US Chemical Safety Board found that relying on injury statistics hid declining process safety at BP Texas City, so pair injury rates with process safety indicators.
Sources
Sources
Public regulator, standards-body and industry sources read on 30 October 2026.
- US Bureau of Labor Statistics, How to compute your firm's incidence rate for safety management
- US Bureau of Labor Statistics, Table 1: Incidence rates by industry and case types, 2024
- US Bureau of Labor Statistics, Employer-Reported Workplace Injuries and Illnesses, 2023-2024
- OSHA, What is the formula to figure DART rate?
- US Chemical Safety Board, BP Texas City findings
- UK HSE, HSG254 Developing process safety indicators
Plan this work in the shutdown module
Book a demo and bring your next shutdown scope. We will show how the work, the permits and the results sit in one plan.