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The reason they stop launches when someone is in the flight path is if there is an accident anyone downwind of rocket fuel is at risk of getting a dose of very poisonous chemicals let alone rocket debris.

No idea how much it costs to scrub a launch and reschedule. Sometimes they have to wait until other scheduled launches are completed. Personnel are typically only there for preparation of the launch and the launch so any delays means paying them more money as well as hassles with extending housing rentals if possible and changing airline departure dates.

Since 9/11 security has been increased and those security officers typically don't have a sense of humor.
 
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