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Item 7. Managements
Discussion and Analysis of Financial Condition and Results of Operations
Overview
We are a North American
mini-mill steel manufacturer, steel pipe producer, and scrap processor, with
facilities in several locations throughout the U.S. and Canada. Our major
products are hot-rolled discrete plate and coil, billets, heat treated plate &
pipe, cut-to-length plate, tubular products and processed scrap metal. We also
provide tubular product finishing services. We operate as a single business
segment. Our tubular and cut-to-length products are produced primarily with our
own coil, which provides added value on our steel products. In favorable market
conditions, we purchase additional coil from third party vendors in order to
optimize utilization at all our facilities. Our customers, located primarily in
the U.S. and Canada, are in the service center, distribution, energy,
agricultural equipment, transportation equipment, heavy machinery and
construction industry sectors. Almost three-quarters of our sales are made to
U.S. customers.
Over the past four years,
our sales have increased from $1.13 billion in 2002 to $3.78 billion in 2006.
Average sales price per ton has increased from $391 per ton in 2002 to $928 per
ton in 2006. Total tons sold have increased 40% from 2.9 million tons in 2002
to 4.1 million tons in 2006. This growth has been generated through an
expansion of our assets and product line sales into U.S. markets.
The following Managements
Discussion and Analysis includes the acquisition of NSG on December 1,
2006 and one month of its operating results.
Results of Operations
2006 Compared to
2005
Revenue of $3.8 billion in
2006 was an increase of $743 million, or 24%, over 2005, resulting from higher
year-over-year prices in all product lines and significant volume increases in
our plate and large diameter product lines. Our average unit selling price
increased to $928 per ton in 2006 from $876 per ton in 2005. Total shipments
increased 608,000 tons compared to last year. Steel mill products increased
375,000 tons or 16% compared to 2005 while tubular increased 233,000 tons or
21% over the same period.
Our average unit selling
price for steel mill products increased $25 per ton to $796 per ton, a 3%
increase over the $771 per ton average price last year. Our average unit
selling price for tubular products increased 8% or $92 per ton to $1,192 per
ton as a result of higher prices in all product lines.
Cost of sales increased
30% to $2.67 billion compared to $2.05 billion in 2005 due to both volume increases
and increases in the average cost per ton. Nearly 60% of the increase was due
to volume. As a manufacturer of steel products, the costs of our products
include scrap steel raw material costs, direct and indirect labor, energy costs
and other direct and indirect manufacturing costs. The primary raw material
used in our operations is steel scrap, which in 2006 represented approximately
41% of the cost of steel products manufactured. Factors that impacted cost of
sales per ton in 2006 were year-over-year increases in the costs of scrap,
alloys, natural gas, electricity and purchased coil inputs, a higher proportion
of purchased versus internally produced coil to our pipe mills and
cut-to-length lines, conversion and yield cost increases, higher freight and
outside conversion costs.
In 2006, a total of $1.3
billion was spent on major raw materials and consumables for our four
steelworks, up 20% from the spending in 2005. Included in this amount are
expenditures for steel scrap, pig iron, alloys, carbon electrodes, oxygen,
refractories, limestone, natural gas and electricity.
The procurement of ferrous
scrap, our largest input, is on a monthly cycle largely through the spot
market. During 2006, we purchased 4.0 million tons of scrap, 15% more than the
prior year. For 2006, the average cost of scrap consumed increased 11%. Scrap
consumption costs peaked mid-year 2006 with some reduction later in the year.
Our internally generated scrap provided 6% of our overall needs. Sourcing for
the remainder of our scrap needs was readily available.
Our electric arc furnaces
consume significant amounts of electricity which contributes a significant
portion of our costs. In 2006, our electricity cost per kilowatt-hour increased
13% and electricity cost per ton of steel produced increased by 9% compared to
2005. Natural gas costs increased 14% compared to 25% in 2005. Energy as a
percentage of 2006 total steel production cost was 10%.
Gross profit increased to
$1.1 billion compared to $981.2 million in 2005 due primarily to the volume
increases mentioned above. Gross margin percentage declined to 29.4% of sales
versus 32.4% in 2005. This margin compression occurred due to increases in
input and conversion costs which more than offset the increases in average
realized pricing.
Shipments: The following table
details tons shipped (in thousands) by major product line.
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2006
Tons Sold
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2006
Tons %
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2005
Tons Sold
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2005
Tons %
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Discrete plate and coil
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2,120
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52
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%
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1,827
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53
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%
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Cut plate
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595
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15
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%
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514
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15
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%
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Energy tubular
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832
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20
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%
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775
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22
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%
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Non-energy tubular
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229
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6
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%
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217
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6
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%
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Large diameter pipe
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293
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7
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%
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128
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4
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%
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Total
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4,069
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100
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%
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3,461
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100
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%
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Shipments to U.S. customers were 3,039,600 tons, 75%
of the total compared to 2,498,200 tons in 2005, while Canadian based customers
accounted for 1,029,000 tons, or 25% in 2006 versus 962,200 in 2005.
Plate shipments increased 16% from 2005 due to strong
end-user demand in transportation, energy and infrastructure markets.
Our coil processing facilities in Houston, St. Paul
and Toronto, all make temper-leveled cut plate products. Shipments of cut plate
from coil processing facilities were 595,000 tons, an increase of 16% from
2005. Canadian shipments increased 14% compared to 2005 levels, while U.S.
shipments increased 16%.
Energy tubular product sales increased 7% or 57,600
tons due to higher oil and gas drilling activity related to the continuing
strength in the oil and gas markets. The average number of active drilling rigs
increased on a year-over-year basis from 1,383 to 1,649 in the U.S. and
increased slightly from 458 to 470 in Canada for a combined increase of 15%.
Shipments of non-energy tubular increased from 217,000 to 228,600, or 5%.
Production:
Capacity utilization is a key driver of performance
for us. Output tonnage is in part a function of the number of production turns
at each facility. Theoretically, all production equipment is available 168
hours a week, less operating downtime for routine maintenance. Therefore, to
maximize plant and equipment utilization and minimize absorbed cost per ton of
output, optimum cost performance occurs when four crews run the facilities
around-the-clock. Optimum utilization after routine maintenance is about 95%.
Capacity,
utilization and production, by facilities, are illustrated in the following
table:
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Utilization (%)
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Production (tons)(1)
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Facility:
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2006
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2005
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2004
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2006
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2005
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2004
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Regina
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90
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92
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91
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1,107
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1,060
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1,001
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Montpelier
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94
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93
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94
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1,297
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1,240
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1,215
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Mobile
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90
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90
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92
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1,424
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1,281
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1,304
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Koppel
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65
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65
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44
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340
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313
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293
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Coil Processing
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36
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33
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35
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600
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514
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562
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Small
Diameter/Welded
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81
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83
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89
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998
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963
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897
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Large Diameter(2)
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69
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42
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36
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300
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188
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197
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Seamless
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81
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80
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79
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277
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265
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242
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(1) In
thousands of tons; based upon liquid steel for steelworks and finished products
for other facilities.
(2) Includes 24 mill
which was not at full capacity
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