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PART I
Item 1. Business
In this Form 10-K,
IPSCO Inc. and its subsidiaries, unless otherwise specified, are collectively
referred to as IPSCO or the Company, and unless the context otherwise
requires, the terms we, us or our refer to the Company.
General
IPSCO is a North American producer of steel products
with facilities located at 25 sites throughout the U.S. and Canada. Four of
these facilities are steelworks; three of which produce carbon steel slabs, hot
rolled discrete plate and coil and one that produces round billets. Downstream
processing facilities further process the plate, coil and billets into
value-added products, including heat treated and normalized plate,
cut-to-length plate, and a comprehensive line of casing, tubing, large and
small diameter line pipe and industrial pipe. Tubular product offerings include
both seamless and welded pipe in carbon and alloy grades.
IPSCO was incorporated by certificate of incorporation
under the laws of Saskatchewan on July 13, 1956 and was continued by
articles of continuance under the Canada Business Corporations Act on January 28,
1977. Originally known as Prairie Pipe Manufacturing Co. Ltd., the name of the
Company was changed to Interprovincial Steel and Pipe Corporation Ltd. on August 26,
1960. On April 2, 1984, the Company changed its name to IPSCO Inc.
On December 1, 2006,
we completed our acquisition of NS Group, Inc. (NSG), a leading producer
of tubular products in the U.S. serving energy and certain other industrial
markets.
Financial
Information about Segments
We operate and report our
business as a single business segment. Our operations are managed, and
operating results are reviewed, as a consolidated enterprise for purposes such
as resource allocation and performance assessment. The Chief Operating Decision
Maker (CODM) and the Board of Directors review profitability for the Company
on a consolidated basis. The financial information reviewed by the CODM is
presented on a consolidated basis which at times includes information by
product only at the levels of gross margins. Allocation of selling, general,
administrative and other costs is not computed between product groupings.
Operating income by product group is not presented in the financial data we
prepare. We believe the information presented in this report meets the
requirements for segment reporting as defined by generally accepted accounting
principles in the United States of America.
Description of
Business
Operations:
We own and operate three flat rolled steelworks in:
Regina, Saskatchewan; Montpelier, Iowa; and Mobile, Alabama. The Regina tubular
operations began in 1956, followed by the steel mill operations in 1961. The
Montpelier Steelworks began production in 1997 and the Mobile Steelworks in
2001. These steelworks use electric arc furnace or mini-mill technology to
convert scrap metal into liquid steel. Alloys are added during processing to
create a variety of steel grades. Liquid steel is cast into slabs and
subsequently hot rolled, using Steckel mill technology, into either discrete
plate or coil.
We own and operate one round billet steelworks, which
we acquired as part of the NSG acquisition with a current estimated annual
meltshop capacity of 450,000 tons which also uses mini-mill technology to
convert scrap metal into liquid steel. Alloys are added during processing to
create a variety of steel grades. Liquid steel is cast into 5½ inches
round billets that are further processed into seamless tubes or sold as
billets.
Five coil-processing
locations, sourced primarily with IPSCO produced coil, fabricate cut-to-length
products. Cut-to-length products are produced from steel coils of various
widths, thicknesses and grades. They are cut to specific lengths to meet
customer requirements in lengths ranging from 8 feet to over 60 feet. We
produce a wide range of cut-to-length products in yield strengths as high as
100,000 pounds per square inch, thicknesses of up to ½ inch and widths as great
as 96 inches.
Seven pipe mill locations
throughout North America utilize both IPSCO and third party coil to fabricate
electric resistance welded (ERW) tubular products that range from 1½ inches to
24 inches in diameter, as well as spiral formed, double submerged arc welded
tubular products greater than 24 inches in diameter. One of the facilities,
located in Wilder, Kentucky was acquired through our NSG acquisition.
Our seamless pipe mill in
Ambridge, Pennsylvania also acquired through our NSG acquisition, heats and
pierces solid steel billets into seamless pipe from 1.9 inches to 5 inches in
outside diameter.
As part of the acquisition
of NSG, we acquired ULTRATM Premium Oilfield
Services Ltd. (ULTRA) which specializes in premium connections, oilfield
accessories and field services for todays complex oil and gas exploration and
production activities with operating facilities in both Odessa and Houston,
Texas. ULTRA is well
positioned to support our growing carbon and alloy tubular market by providing
the highly regarded line of ULTRA premium
connections.
We operate five auto
shredder facilities in Western Canada and nine smaller scrap metal processing
and auto wrecking yards. These supply a significant portion of the scrap metal
requirements of our Regina Steelworks as well as selling scrap to third parties
in addition to processing non-ferrous materials that are sold throughout the
world.
With the acquisition of
NSG on December 1, 2006, our workforce increased by approximately 1,500 to
4,400 employees. On an annual basis, steel production volumes exceed 4 million
tons. Acquisition and investment in new facilities and technology in the U.S.,
combined with training of production employees, have allowed us to expand
production volumes through improved efficiencies. We believe we have a high
rate of employee retention as a result of providing industry competitive wages
that are supplemented by profit-driven incentives for achieving production,
safety, on time shipment and other targets.
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