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Special Steels India Business Unit
1. Gerdau Group
2. Special Steels Business Unit
3. India Business Unit
Global Presence
• 111 years in business
• Production facilities in 14 countries
• 60 steel mills
• Near 46,000 employees
• Crude steel capacity of 25.3 million tons
• Ranked 10th in the world by 2010 steel output
• 2nd largest long steel producer in the world and the 1st in the Americas
Gerdau Profile
Map Legend Show
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Company’s Philosophy
Vision
To be a GLOBAL ORGANIZATION and a BENCHMARK in any business we conduct
Mission
To CREATE VALUE for our customers, shareholders, employees, and communities by
operating as a SUSTAINABLE steel business
Be the CUSTOMERS choice
SAFETY above all
Respected, engaged and fulfilled EMPLOYEES
Pursuing EXCELLENCE with SIMPLICITY
Focus on RESULTS
INTEGRITY with all stakeholders
Economic, social and environmental SUSTAINIBILITY
Values
110 Years in Business
1900 40’s 50’s 60’s 70’s 80’s 90’s 2000
Expansion in Brazil
Expansion Abroad
1901:
1St operation: (nail factory)
1948:
1St mill acquisition (Riograndense)
Expansion of Riograndense
(construction of 2nd steel mill)
Market Share Increase - Diversification / downstream
- Own distribution network -Acquisition of one mill
(Pernambuco)
Acquisition of one mill (Paraná)
Construction of a new mill (Rio de Janeiro)
1St mill acquisition abroad (Uruguay)
1St mill Acquisition in North America
(Canada)
Acquisition of 3 mills (Rio de Janeiro,
Minas Gerais and Bahia)
Construction of 2 new mills
(Paraná and Ceará)
Acquisition of Piratini
(Specialty steel)
Second mill in Minas Gerais
Entering in Açominas
Mills acquisitions (Chile, Canada,
Argentina and USA)
Acquisitions in USA (Chaparral, MacSteel)
Entering in Europe and Asia
(Spain and India)
Expansion in Latin America
Construction of a steel mill
(São Paulo)
Acquisition in USA (TAMCO)
16.3
16.5
16.7
16.8
17.9
19.9
20.5
22.0
23.8
24.0
29.8
29.9
30.0
31.9
33.4
37.7
39.1
43.3
44.4
97.2
2011 Top Steel Producers
Source: World Steel Association www.worldsteel.org
Million metric tons crude steel production
- ArcelorMittal
- Heibei Group
- Baosteel Group
- POSCO
- Wuhan
- Nippon Steel
- Shagang Group
- Shougang Group
- JFE
- Ansteel Group
- Shangdong Group
- Tata Steel
- United States Steel
- Gerdau
- Nucor
- ThyssenKrupp
- Evraz
- Maanshan
- Benxi
- Hyundai
1º
2º
3º
4º
5º
6º
7º
8º
9º
10º
11º
12º
13º
14º
15º
16º
17º
18º
19º
20º
2010
2005
2000
2011
- ArcelorMittal 1º
- Gerdau 2º
- Evraz 3º
- Tata Steel 4º
- Nippon Steel 5º
- JFE 7º
- Nucor 8º
- Riva 9º
- Celsa Group 10º
- Industrial Union of Dombass 6º
47.3
19.5
14.7
10.7
10.5
10.1
9.5
8.9
8.6
8.2
Source: Steel on the Net www.steelonthenet.com
2010 Top Long Steel Producer’s Capacities
Million metric tons long steel capacity
8.6
8.8
8.9
9.4
10
10.8
11.1
18.7
22.6
51.2
Products and End Users
• Billets, blooms & slabs
• Merchant bars
• SBQ
• Wire-rod
• Rebars
• Fabricated steel
• Heavy structural shapes
• Nails
• Wires
Products End Users
• Housing
• Infrastructure
• Agricultural sector
• Automotive industry
• Oil and gas sector
• Shipbuilding
• Wind power generation
• Mining
• Other industrial sectors
1st Quarter
20122011 2010 2009 2008
Net Revenues (US$ million) 4,972 20,233 18,798 13,408 22,618
Net Income (US$ million) 215 1,199 1,471 577 2,832
Total assets (US$ million) 26,826 28,499 25,683 25,605 33,914
Total shipments (thousand tonnes) 4,725 19,164 17,363 13,987 19,118
Total Output (thousand tonnes) 4,940 19,623 17,852 13,509 19,599
EBITDA (US$ million) 545 2,658 3,114 1,999 5,488
EBITDA Margin (%) 11% 13% 17% 14% 24%
Gross Margin (%) 12% 14% 18% 17% 26%
Key Financial Figures
Investment Plan (2011 – 15)
USD 6.05 billion in five years
• Heavy plate rolling mill at Ouro Branco unit
• Structural beam rolling mill expansion at Ouro Branco unit
• Commercialization of iron ore resources
• Wire rod and rebar rolling mills in Santa Cruz unit
Investment Installed capacity
Goal
USD 57 million 700 thousand tons in 2011
Expansion of mining capacity to 7 million tons Self sufficiency for 100% of Ouro Branco unit iron ore needs
USD 1.0 billion 1 million tons by the end of 2012 grow in oil and gas, shipbuilding and construction sectors
Investment Future capacity
Annual Production Goal
Investment Installed capacity
Goal
USD 1.5 billion Additional 600 thousand tons in 2013 Participate in demand due to FIFA World Cup and Rio Olympics
Board of Directors Board of Directors
Corporate Governance
Business Units
General Assembly
Functional Processes
Gerdau Executive Committee (GEC)
Board of Directors
Dr. Jorge Gerdau Johannpeter
Germano H. Gerdau Johannpeter
Klaus Gerdau Johannpeter
Frederico C. Gerdau Johannpeter
Expedito Luz General Secretary:
Affonso Celso Pastore
André Pinheiro de Lara Resende
Oscar de Paula Bernardes Neto
Cláudio Gerdau Johannpeter
André Gerdau Johannpeter
Presid
en
t V
ice-P
resid
en
ts
Cou
nselo
rs
Alfredo Huallem
Board of Directors
Gerdau Executive Committee (GEC)
Corporate Governance
Business Units
General Assembly
Functional Processes
Gerdau Executive Committee (GEC)
CLÁUDIO Gerdau Johannpeter
Osvaldo Burgos SCHIRMER
Manoel VITOR de Mendonça Filho
ANDRÉ Gerdau Johannpeter
EXPEDITO Luz
CFO COO Executive VP CEO
Executive VP
Ricardo Giuzeppe MASCHERONI
Executive VP
FRANCISCO Deppermann Fortes
Executive VP
Gerdau Executive Committee (GEC)
Board of Directors
Business Units
Corporate Governance
General Assembly
Functional Processes
Wire rod
Wires
Merchant Bars
Business Operations
GERDAU
Brazil
Long and Flat Steel North America Special Steels
Latin America North
Billets, blooms & slabs Heavy Structural Shapes
Rebars Fabricated Steel
Nails
Rolling Mill Rolls
Forged and Cast Parts
Long Steel
34% 6% 34% 20%
SBQ - Bar
SBQ - Wire rod
% of 2011 net sales
Latin America South
6%
Hot Rolled Coils Hot Rolled Heavy Plates
1. Gerdau Group
2. Special Steels Business Unit
3. India Business Unit
Brazil
Long and Flat Steel
Organizational Chart
Mr. Mark Marcucci Special Steels and India
VP
Mr. Luis Colembergue Operations
USA
Mr. Jack Finlayson
Spain
Mr. Jose Jainaga
Brazil
Mr. Joaquim Bauer
GERDAU
Latin America South North America Special Steels Latin America North
Long Steel
34% 6% 6% 20%
% of 2011 net sales
India
Mr. Arvind Mathur
34%
USA
Brazil
Spain
India
China
Locations
12 steel mills + 1 under construction
11 downstream units
10 representative offices
• 12 steel mills in 3 countries + 1 joint venture steel mill under construction in India
• Ranked 2nd in 2008 SBQ global sales
• Largest supplier of SBQ to the automotive industry in the world
• Installed capacity over 3.7 million metric tons of crude steel
• Near 8,100 employees
Special Steels Profile
102 126 149 139 120172 168 211
264 260 273 309379 388 374
754
3,214
1,870
2,796
2967
Control of Aços Villares
Entry in Europe
Entry in India
20+ Years of Special Steel Expertise
Expansion in Brazil
Expansion Abroad
Piratini mill acquisition
Kalyani Gerdau Steel
Ltd. Established
(JV Kalyani Group)
Acquisition of Sidenor
Acquisition of Aços Villares
Monroe Melt Shop Improvements
Construction of a new rolling mill in
Pindamonhangaba
1990 2006 2008 2000 1990 2006 2008 2000 2010 2012 2010 2012
Acquisition of MacSteel
US$ 1.5 billion in 2011 - 13
Entry in North America
Installation of new rolling mill at Piratini
Improvements in the continuous caster at
Pirantini
Installation of downstream
facilities at Piratini
Mordernization of melt shop at Piratini
Increase in production capacity of melt shop at Piratini
Increase in rolling mill L1 capacity at
Piratini
Investment Plan (2012 – 14)
USD 67 million Additional capacity of 200,000 tons by end of 2013
USD 322 million Additional capacity of 400,000 tons by 2014 Competitive special steel solutions to a fast recovering industry
USD 205 million 500,000 tons by the end of 2012 Accompany growth of the automotive sector in Brazil
USD 169 million approved 300,000 tons/year Strategic unit: first in Asia
• Special steel rolling mill in Brazil
• Improvement in melt shop with new continuous caster in USA
• Capacity expansion at 2 different mills in USA
• Investments in Kalyani Gerdau JV in India
USD 1.5 billion in three years
Investment Installed capacity
Goal
Investment Future capacity
Investment Future Capacity
Goal
Investment Future Capacity
Goal
Brazil
• Company Name: Gerdau
• Steel Mills: 4
• Downstream Units: 0
• Representative Offices: 1
• Employees: 4,200
• Crude Steel Capacity (1,000 metric t): 1,380
• Rolled Steel Capacity (1,000 metric t): 1,340
• Rolling Mill Rolls Capacity (1,000 metric t): 40
• Product Portfolio: SBQ, Stainless and Rolling Mill Rolls
General Info
- Steel Mills - Representative Offices
620,000 t
570,000 t
40,000 t
Brazil
Steel Mills
Pindamonhangaba
• Crude Steel Capacity:
• Rolled Steel Capacity:
• Rolling Mill Rolls Capacity:
Sorocaba
• Rolled Steel Capacity:
Mogi das Cruzes
• Crude Steel Capacity:
• Rolled Steel Capacity:
Charqueadas
• Crude Steel Capacity:
• Rolled Steel Capacity:
• Forged Steel Capacity:
30,000 t
360,000 t
190,000 t
400,000 t
550,000 t
25,000 t
- Steel Mills - Representative Offices
Industrial Capabilities – SBQ and Stainless
• Pindamonhangaba • Charqueadas • Mogi das Cruzes • Sorocaba
95 t/heat 65 t/heat 70 t/heat
VD VD/VOD VD
3.2 to 6.9 t 1.3 to 7.3 t
155 mm 150 and 240 mm 155 and 185 mm
152.4 to 560 mm
63.5 to 410 mm
2 to 31 mm 4 to 30 mm
10 to 125 mm 18 to 80 mm
10 to 100 mm 15 to 52 mm
10 to 76 mm 10 to 105 mm 14 to 130 mm
8 5 2
17.4 to 228.6 mm
76.2 to 129 mm
50 to 88.9 mm
66.7 to 450 mm
15.8 to 203 mm
50 to 82.5 mm
4.4 to 60 x 17 to 145 mm
5.5 to 33.3 mm 5.5 to 30.1 mm
4.7 to 8.2 x 60 to 90 mm
Square bars
Forging Mill Round bars
Drawing
Grinding
Inspection Lines
Number of lines
Sizes
Rolling Mill Round bars
Square bars
Flat bars
Wire Rod
Types
Heat Treatment
Ingot casting
EAF
Degassing
Billet casting
Bloom casting
Melt Shop
Other (special profile)
Cold Finishing Turning
Q+T, Annealing and Spheroidizing
Q+T, Annealing and Spheroidizing
Q+T, Annealing and Spheroidizing
5.4 to 32 x 70 to 102 mm
Spain
• Company Name: Gerdau Sidenor
• Steel Mills: 5
• Downstream Units: 5
• Representative Offices: 5
• Employees: 2,600
• Crude Steel Capacity (1,000 metric t): 1,080
• Rolled Steel Capacity (1,000 metric t): 1,040
• Forged and Casted Parts Capacity (1,000 metric t): 70
• Product Portfolio: SBQ, Stainless, Rolling Mill Rolls and Forged and Cast Parts
General Info
- Steel Mills - Representative Offices - Downstream units
Spain
Steel Mills
Basauri
• Crude Steel Capacity:
• Rolled Steel Capacity:
Reinosa
• Crude Steel Capacity:
• Rolled Steel Capacity:
• Parts Capacity:
Azkoitia
• Rolled Steel Capacity:
Vitoria
• Rolled Steel Capacity:
690,000 t
250,000 t
340,000 t
180,000 t
360,000 t
Legazpi
• Crude Steel Capacity:
• Rolled Steel Capacity:
140,000 t
10,000 t
70,000 t
150,000 t
- Steel Mills - Representative Offices - Downstream units
Industrial Capabilities – SBQ and Stainless
• Basauri • Reinosa
220 to 1500 mm
350 to 2500 mm
• Vitoria • Legazpi • Azkoitia
20 to 100 mm 95 to 300 mm
5 to 36 mm
19 to 30 mm 20 to 82 mm
Inspection Lines
Number of lines
Sizes 25 to 100 mm
4
10 to 220 mm
1 5
20 to 80 mm
4
20 to 200 mm
Rolling Mill Round bars
Square bars
Flat bars
Wire Rod
Other
25 to 100 mm
70 to 170 mm
100 to 230 mm
5.5 to 38 mm
1.5 to 15 x 1000 x 2000 mm
20 to 200 mm
65 to 200 mm
Q+T and Annealing
VD/AD
Ingot casting
EAF
Degassing
Billet casting
Bloom casting
145 t/heat
VD/VOD
155 and 180 mm
300 x 400 mm
70 t/heat
VD/AD
3.1 t
50 t/heat
2.5 t
310 x 240 mm
Melt Shop
(flat steel)
20 to 45 mm
Q+T and Annealing Q+T and Annealing Q+T and Annealing Q+T and Annealing
Square bars
Forging Mill Round bars
Drawing
Grinding
Types
Heat Treatment
Cold Finishing Turning
7 to 40 mm 35 to 88,9 mm
6 to 92 x 50 to 350 mm
Forjanor Villalba
• Business:
Forging
Legutiano
• Business:
Cold drawing
Spain
Downstream Units
Maltzaga
• Business:
Cold drawing and turning
Forjanor Elgeta
• Business:
Forging
Polinya
• Business:
Cold drawing and turning
- Steel Mills - Representative Offices - Downstream units
USA
• Company Name: Gerdau MacSteel
• Steel Mills: 3
• Downstream Units: 6
• Representative Offices: 2
• Employees: 1,700
• Crude Steel Capacity (1,000 metric t): 1,180
• Rolled Steel Capacity (1,000 metric t): 1,100
• Product Portfolio: SBQ
General Info
- Steel Mills - Representative Offices - Downstream units
USA
Steel Mills
Jackson
• Crude Steel Capacity:
• Rolled Steel Capacity:
Monroe
• Crude Steel Capacity:
• Rolled Steel Capacity:
Fort Smith
• Crude Steel Capacity:
• Rolled Steel Capacity:
250,000 t
470,000 t
460,000 t
440,000 t
230,000 t
430,000 t
- Steel Mills - Representative Offices - Downstream units
• Jackson • Fort Smith
Industrial Capabilities – SBQ
54 t/heat
VD
28 to 132 mm
31.8 to 127 mm
3
44.4 to 153 mm
• Monroe
25.4 to 88.9 mm
2
25 to 82.5 mm
14.2 to 82.55 mm
46 t/heat 128 t/heat
VAD VAD
178 and 237 mm 160 and 195 mm 152 mm
25.4 to 108 mm
19.05 to 82.5 mm
2
22 to 85 mm Inspection Lines
Number of lines
Sizes
Rolling Mill Round bars
Square bars
Flat bars
Wire Rod
Other
Ingot casting
EAF
Degassing
Billet casting
Bloom casting
Melt Shop
Square bars
Drawing
Grinding
Types
Heat Treatment
Cold Finishing Turning
Forging Mill Round bars
Annealing and Spheroidizing Annealing and Spheroidizing Annealing and Spheroidizing
USA Downstream Units
Lansing - Basset
• Business:
Forged parts coating and heat treating
Lansing – Mt. Hope
• Business:
Forged parts coating and heat treating
Pleasant Prairie
• Business:
Surface treatment (Nitrosteel)
Huntington
• Business:
Heat treatment (Quench & temper)
North Vernon
• Business:
Forged parts coating and heat treating
Canton
• Business:
Forged parts coating and heat treating - Steel Mills - Representative Offices - Downstream units
• Hot Rolled Bars
- Rounds
- RCS
- Flats
- Special Profiles
Product Portfolio: SBQ
Products
Applications
• Forged Bars • Wire Rod
- Coils
Grades
- Rounds
- RCS
- Flats
• Carbon
• Alloyed
• Micro alloyed
• Free cutting
- International specifications (SAE, DIN, AFNOR and others)
- Customers specifications
• Automotive • Non-Automotive
- Trains
- Energy (oil and gas; wind power)
- Mining
- Heavy machinery
- Agricultural equipment - Powertrain
- Suspension
- Steering
Conrods Gears Crankshafts - Camshafts - Bearings - Fasteners - Shafts
Coil springs
- Shock absorbers - Clamps - Fasteners
Leaf springs Stabilizer bars
Gear racks Wheel hubs
- Bearings - Shafts - Fasteners
Some of Our Valued Customers
Vehicles in Which Gerdau Steel Can be Found
Research and Development
• 3 research centers (Brazil, Spain and USA)
• The second best research center in the steel industry in Europe
• The best research center in the long steel industry in the Americas
• 200 engineers working with product and process development • 3,000 different steel grades every year
• 100 process development projects developed in 2007
• 1,000 product development projects in 2007 (PPAP - Production Part Approval Process )
General Info
Areas of Expertise
Steel for Automotive Components
- Conrods
- Crankshafts
- Camshafts
Engine
- Constant velocity joints (CVJs)
- Gears
Transmission
- Gear racks
- Drive shafts
Steering System
- Springs
- Shock absorbers
Suspension
- Bearings
- Fasteners
Various Systems
Parts Systems
Areas of Expertise
Steel for Non-Automotive Sectors
Energy (Wind Power, Oil and Gas)
Agricultural Equipment
Applications Sectors
Mining
Trains
Other
- Tractors components
- Subsea equipments components
- Fasteners for wind power equipment
- Grinding bars
- Electrodes for aluminum production
- Springs
- Axles
- Hand tools
- Shafts for electric motors
- Harvester blades
- Mooring chains for offshore rigs
Projects and Partnerships with Think Tanks
BFI-VDEH
Fraunhofer-Institut
IMA GmbH Dresden
IAS
Senai Cetemp
CRM
Vitkovice R&D
CEIT
Inasmet
Labein
Irsid
Leces
Pole Univesitaire Leonard de Vinci
CSM
Istituto Nazionale Galileo Ferraris
Instytut Metallurgii Zelaza
ISQ
Institutet För Metallfrskning AB
IVL
Kimab
Mefos
ASPPRC
NCMC
AISI
AIST
FIERF
FIA
ASPEX
Projects and Partnerships with Universities
Univ. Aachen
Univ. Freiberg
UFRGS
Unisinos
USP
Unicamp
UFSCar
Univ. BRNO
Univ. Mondragon
Univ. Oviedo
Univ. Pisa
Colorado School of Mines
Carnegie Mellon
Univ. of Toledo
Univ. Bristol
Projects and Partnerships with Companies
ALD
Dillinger
Georgsmarienhutte
Saarstahl
TKN
TKS
Aceralia (ArcelorMittal)
Tecnatom
Ovako-Imatra
Rautaruukki Oyj
Voestalpine Stahl
Acciai Speciali Terni
Cogne
Gianetti-Magnetto
Profilarbed (ArcelorMittal)
Corus
Outokumpu
Sandvik
Uddeholm
Daido
Sumitomo
Sanyo
Ascometal
1. Gerdau Group
2. Special Steels Business Unit
3. India Business Unit
•Company Name: Gerdau Steel India Ltd. • Mill Location: Tadipatri
• Office Location: Bangalore
• Product Portfolio: SBQ
Gerdau Steel India Ltd.
General Info
Tadipatri
• Crude Steel Capacity:
• Rolled Steel Capacity:
Steel Mill
300,000 t
300,000 t
Tadipatri
Bangalore
- Steel Mill - Office
Gerdau Steel India Ltd. Project History
Current Status
2007 2008 2009 2010
SJK Steel acquired to form a JV between
Kalyani Group and Gerdau Group
Project on hold due to global financial crisis
2011 2012
Project CAPEX approved for
300,000 tons
On Going Projects - Rolling Mill - Sinter Plant - PowerPlant
- SMS upgrades - Coke Oven - Township
Rolling Mill start - up
2013
Gerdau takes over Kalyanis
stake
Rolling Mill 1
BF 1
350 m3
BOF 1
35t
BOF 2
35t
LF 1
35t
CCM 1
3 x 150 mm 6m radius
Clients
VD 1
35 t Sinter 1 33 m2
PCM
Existing Approved Projects
CPP
6 MW
Configuration: 1,000,000 tons liquid metal
Iron Making Melt Shop Rolling Mill
SBQ: 300,000 t/y
Ø 16-65 mm
P R O D U C T S
Configuration: 300,000 tons liquid metal Project Scope
CCM 1
3 x 130 mm 6m radius
Inspection
Coke Oven
CPP
15 MW
PCI
Mines
Phase II Expansion
Iron Making Melt Shop Rolling Mill
Configuration: 1.2 million tons liquid steel
CPP 2
CPP 3
CPP 4
15 MW
15 MW
15 MW
Coke Oven
Existing Phase I (Under
Implementation) Phase II
4 Battery
4 Battery
4 Battery
Sinter 1
Sinter 2
33 m2 80 m2
Pellet Plant
400 kt/y
PCM
108 t/h
BF 1
BF 2
350 m3 900 m3
BOF 1
35 t
BOF 2
35 t
BOF 3
35 t
LF 1
35 t
LF 2
35 t
VD 1
35 t
VD 3
75 t
CCM 1
150 x 150 mm
6/11 m radius
CCM 2
160 x 160 mm
9/15 m radius
BOF 4
75 t
LF 3
75 t
LF 4
75 t
CCM 3
260 x 320 mm
120 x 120 mm
12/18 m radius
VD 2
35 t
RM 1
SBQ: Ø 16-70 mm
300 kt/y
RM 3
Wire Rod: Ø 5-17.5 mm
420 kt/y
RM 2
SBQ: Ø 50-140 mm
500 kt/y
Customers
Inspection
Inspection
CPP 1
CPP 5
6 MW 15 MW
PCI 1
PCI 2
Benefication
Special Steel: Long-Term Vision
- Quality of products and services
- Proximity to customers
- Product development
- World-Class operation
- Management technology
To be the global supplier of choice in special steel business
Special Steel Business Operation is core in Gerdau’s strategy
Is proud to announce
‘LK Group’
of companies as their
distributors for marketing
their products.
Thanks