Flat Roll Group, Butler Division

The Flat Roll Group’s Butler Division based at Butler, Indiana, was SDI’s first mill. 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 minimills 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 the per man-hour labor required to produce a ton of HRC to about 0.25, or about 1/4 of an hour.

In 2003, we acquired a modern galvanizing plant at Jeffersonville, Indiana, out of bankruptcy. Using steel supplied by Butler, it became a part of the Flat Roll Group’s Butler Division. Both the Butler and Jeffersonville facilities now include paint lines for coating steel coils.

Today, the Butler 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 in 2014

3 million tons