Flat Roll Division
The Flat Roll Division based at Butler, Indiana, was SDI’s first mill and remains the company’s largest operation. After its start-up at the beginning of 1996, the division soon became profitable. Its success enabled Steel Dynamics to go public in November 1996 and supported the company’s continued growth and diversification. This included the expansion of the Butler mill itself in 1997-98 to double its steelmaking capability and to add a cold-finishing mill.
Today, the Butler Flat Roll complex is one of the most productive and profitable flat-roll mini mills in the world. Its production capacity has increased incrementally over the years to reach 3.0 million tons per year. With its growth, we have compressed steel production cost and reduced to about a quarter of a man-hour the labor applied to produce a ton of HRC.
In 2003 we acquired out of bankruptcy a modern galvanizing plant at Jeffersonville, Indiana. Using steel supplied by Butler, it became a part of the Flat Roll Division. Both the Butler and Jeffersonville facilities now include paint lines for coating steel coils.
Today, the Flat Roll Division produces a wide range of sheet steel products and— through steel distributors and direct sales to OEMs—serves a number of end markets, including automotive, appliance, residential and non-residential construction, energy, agriculture, commercial and industrial markets.
Annual production capacity, HRC
3 million tons
Percent of SDI steel shipments, 2012
HRC and finished steel, Butler and Jeffersonville