Nucor Steel–Indiana, Crawfordsville, Ind.
As the first continuous thin-slab cast flat rolled steelmaking facility in the world, Nucor Steel–Indiana, Crawfordsville, Ind., has an annual capacity of 2,200,000 tons of hot rolled, cold rolled and galvanized products. The mill serves a broad range of customers, including service centers/processors, pipe and tube, construction, agricultural, electrical and others. The continuous thin-slab cast flat rolled steelmaking process transforms molten metal into hot band in an uninterrupted operation. The plant’s pickling and cold rolling operations have an annual capacity of 1.5 million and 1 million tons, respectively. Nucor Steel–Indiana has one of the most cost-effective galvanizing lines in the country, with an annual capacity of 375,000 tons.
The wide product offering includes:
• Carbon ranges through 1085, drawing quality, high-strength low-alloy up to Grade 80, and motor lamination steels.
• Hot rolled coils, hot rolled skinpassed coils, hot rolled pickled and oiled coils.
• Cold rolled and galvanized coils.
Nucor Steel–Indiana is the site of the world’s first commercial compact strip plant (CSP), built in 1989, as well as the site of the world’s first commercial Castrip® twin-roll carbon steel caster. The plant consists of a 6-stand hot mill and two downcoilers, a 1 million tpy cold mill and a hot-dip galvanizing line.
Nucor Steel–Indiana has rolled more than 33 million tons since its 1989 start-up. In the past, the plant has shipped more than 2 million tons in a year.
This tour will NOT include Castrip.
Nucor Steel–Indiana has achieved TS 16949 (quality) and ISO 14001 (environmental) certifications. The plant employs 735 people.
Steel Dynamics Inc., Pittsboro, Ind.
In September 2002, Steel Dynamics Inc. (SDI) bought the Pittsboro, Ind., minimill assets of Qualitech Steel SBQ LLC for $45 million. This facility, in which Qualitech had invested more than $350 million, opened in 1998, but was shuttered after about two years due to the company’s difficulties entering the special bar quality (SBQ) steel market. The mill is located along Interstate 74 about 14 miles west of Indianapolis on approximately 200 acres with more than 650,000 square feet under roof. SDI’s Engineered Bar Products Division employs approximately 340 people.
The facility was originally designed to produce a high-quality SBQ product, but the mill’s layout and equipment had certain limitations. Before buying the mill, SDI fully evaluated the mill’s configuration and capabilities, and concluded that an additional investment of about $75 million would be needed to rectify the mill’s shortcomings and better equip it for efficient production of an even greater array of demanding SBQ products for its customers.
On 1 Sept. 2003, SDI received the Indiana environmental permit needed to proceed with construction and modifications at the mill. This work commenced immediately, and the first production of steel bars occurred in December 2003.
The SDI Engineered Bar Products Division supplies carbon, resulfurized, alloy, microalloy and specialty steel grades from 1.5-through 9-inch rounds and 2.5- through8-inch round corner squares (RCS) to the SBQ market. Typical markets served include service centers and distributors, forging, cold finishing, tubing, automotive, heavy truck and construction equipment segments.
SDI has attained ISO 9001:2000 accreditation and continues to expand its products and processes to include bar inspection, bar turning, saw cutting, straightening and heat treating in its newly constructed bar finishing facility.