ThyssenKrupp Steel and Stainless USA
An Alabama Engineering Marvel
Inducted in 2011
A world-class, carbon-steel-processing facility and engineering marvel in Calvert, Ala., ThyssenKrupp Steel and Stainless USA will provide high-quality products for customers in the automotive, construction, pipe and tube, service and appliance industries. While protecting the environment and displaying a high regard for safety, the $4.6 billion project has created infinite opportunities for Alabama.
The enormous complex covers 5.6 square miles with seven million square feet under roof. The facility includes a state-of-the-art river terminal, a rail terminal, a hot strip mill, a cold-rolling mill, a wastewater treatment system and four hot dip-coating lines. By the time the plant is fully operational, it will process 5.3 million metric tons of carbon steel annually, which includes 4.4 million tons of carbon steel and one million tons of stainless. The facility’s cooperative production of steel creates a unique, innovative, cross-segment partnership that enables cost sharing in areas such as infrastructure, logistics and some processing.
The project is believed to be one of the largest private-industrial investments in the U.S. and is a rare case of job in-sourcing for the country. The complex will create an estimated 2,700 permanent jobs in Alabama when it becomes fully operational. Over 5,200 workers were on-site during the various phases of construction, providing great opportunities for many area businesses. ThyssenKrupp has invested nearly $750 million with Alabama companies, approximately $192 million with Mobile-area companies and another $1 billion with other Southeastern-based companies.
ThyssenKrupp strongly believes in protecting the environment. Throughout three years of construction, the company has been attentive to the environment by assisting in protecting wetlands, using recyclable materials and providing the highest level of energy efficiency. In addition, extra fencing was installed to protect the threatened Alabama black bear.
In 2009, the project’s safety-incident rate was less than half of the national average for a heavy-construction site. In many instances, ThyssenKrupp has instituted practices that exceeded Occupational Safety and Health Administration guidelines. Earlier this year, the company entered into a strategic partnership with OSHA designed to encourage, assist and recognize efforts to eliminate serious hazards and achieve model workplace safety and health practices.
ThyssenKrupp is one of the world’s largest integrated materials and technology companies. The group of companies is headquartered in Düsseldorf, Germany, with operations in 80 countries and over 199,000 employees. It is one of the top 10 companies in Germany, with $61 billion in annual revenue. The company has steel, stainless, elevator and technology subsidiaries.
In the U.S., there are 70 companies in more than 400 locations, with about 25,000 employees and more than $9.5 billion in annual sales. Through its predecessor companies, ThyssenKrupp has been part of the U.S. historical landscape for 170 years, dating back to 1837 when Alfred Krupp, founder of predecessor company Krupp, provided coin-minting-machine prototypes to the U.S.