UNITED
STATES SECURITIES AND EXCHANGE COMMISSION
Washington, D.C.
20549
FORM
1O-K
(Mark One)
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Annual report pursuant to Section 13 or 15(d) of the
Securities Exchange Act of 1934
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for the fiscal year ended December 31, 2006
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Transition report pursuant to Section 13 or 15(d) of the
Securities Exchange Act of 1934
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for the transition period from to
Commission file number 1-12001
ALLEGHENY
TECHNOLOGIES INCORPORATED
(Exact name of registrant as specified in its charter)
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Delaware
(State or other jurisdiction of incorporation
or organization)
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25-1792394
(I.R.S. Employer
Identification Number)
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1000 Six PPG Place, Pittsburgh, Pennsylvania
(Address of principal executive offices)
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15222-5479
(Zip Code)
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Registrants telephone number, including area code: (412) 394-2800
Securities registered pursuant to Section 12(b) of the Act:
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Title of each class
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Name of each exchange on which registered
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Common Stock, $0.10 Par Value
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New York Stock Exchange
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Preferred Stock Purchase Rights
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New York Stock Exchange
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Securities registered pursuant to Section 12(g) of the Act: None
Indicate by check mark whether the Registrant is well known seasoned issuer, as defined in
Rule 405 of the Securities Act.
Yes
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No
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Indicate by check mark if the Registrant is not required to file reports pursuant to Section
13 or Section 15(d) of the Act.
Yes
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No
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Indicate by check mark whether the Registrant (1) has filed all reports required to be filed
by Section 13 or 15(d) of the Securities Exchange Act of 1934 during the preceding 12 months, and
(2) has been subject to such filing requirements for the past 90 days. Yes
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No
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Indicate by check mark if disclosure of delinquent filers pursuant to Item 405 of Regulation
S-K is not contained herein, and will not be contained, to the best of Registrants knowledge, in
definitive proxy or information statements incorporated by reference in Part III of this Form 10-K
or any amendment to this Form 10-K.
þ
Indicate by check mark whether the Registrant is a large accelerated filer, an accelerated
filer, or a non-accelerated filer. See definition of accelerated filer and large accelerated
filer in Rule 12b-2 of the Exchange Act.
Large accelerated filer
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Accelerated filer
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Non-accelerated filer
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Indicate by check mark whether the Registrant is a shell company (as defined in Rule 12b-2 of
the Exchange Act).
Yes
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No
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On February 14, 2007, the Registrant had outstanding 101,983,940 shares of its Common Stock.
The aggregate market value of the Registrants voting stock held by non-affiliates at June 30, 2006
was approximately $6.82 billion, based on the closing price per share of Common Stock on that date
of $69.24 as reported on the New York Stock Exchange, and at February 14, 2007 was approximately
$10.0 billion, based on the closing price per share of Common Stock on that date of $100.69 as
reported on the New York Stock Exchange. Shares of Common Stock known by the Registrant to be
beneficially owned by directors and officers of the Registrant subject to the
reporting and other requirements of Section 16 of the Securities Exchange Act of 1934, as amended
(the Exchange Act), are not included in the computation. The Registrant, however, has made no
determination that such persons are affiliates within the meaning of Rule 12b-2 under the
Exchange Act.
Documents Incorporated By Reference
Selected
portions of the Proxy Statement for the Annual Meeting of
Stockholders to be held on May 2, 2007 are incorporated by
reference into Part III of this
Report.
INDEX
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Page
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Number
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PART I
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3
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Item 1.
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Business
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3
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Item 1A.
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Risk Factors
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11
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Item 1B.
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Unresolved Staff Comments
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15
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Item 2.
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Properties
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15
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Item 3.
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Legal Proceedings
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16
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Item 4.
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Submission of Matters to a Vote of Security Holders
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17
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PART II
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17
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Item 5.
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Market for the Registrants Common Equity, Related Stockholder Matters
and Issuer Purchases of Equity Securities
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17
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Item 6.
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Selected Financial Data
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18
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Item 7.
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Managements Discussion and Analysis of Financial Condition and Results
of Operations
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21
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Item 7A.
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Quantitative and Qualitative Disclosures About Market Risk
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52
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Item 8.
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Financial Statements and Supplementary Data
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53
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Item 9.
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Changes in and Disagreements with Accountants on Accounting and
Financial Disclosure
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89
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Item 9A.
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Controls and Procedures
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89
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Item 9B.
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Other Information
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93
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PART III
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93
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Item 10.
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Directors, Executive Officers and Corporate Governance
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93
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Item 11.
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Executive Compensation
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93
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Item 12.
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Security Ownership of Certain Beneficial Owners and Management and
Related Stockholder Matters
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93
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Item 13.
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Certain Relationships and Related Transactions and Director Independence
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94
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Item 14.
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Principal Accounting Fees and Services
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94
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PART IV
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94
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Item 15.
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Exhibits, Financial Statement Schedules
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94
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SIGNATURES
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98
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EX-12.1
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EX-21.1
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EX-23.1
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EX-31.1
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EX-31.2
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EX-32.1
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2
PART I
Item 1. Business
The Company
Allegheny Technologies Incorporated (ATI) is a Delaware corporation with its principal executive
offices located at 1000 Six PPG Place, Pittsburgh, Pennsylvania 15222-5479, telephone number (412)
394-2800. Allegheny Technologies was formed on August 15, 1996 as a result of the combination of
Allegheny Ludlum Corporation and Teledyne, Inc. References to Allegheny Technologies, ATI, the
Company, the Registrant, we, our and us and similar terms mean Allegheny Technologies
Incorporated and its subsidiaries, unless the context otherwise requires.
Our Business
Allegheny Technologies is one of the largest and most diversified specialty metals producers
in the world. We use innovative technologies to offer growing global markets a wide range of
specialty metals solutions. Our products include titanium and titanium alloys, nickel-based alloys
and superalloys, zirconium, hafnium and niobium, stainless and specialty steel alloys,
grain-oriented silicon electrical steel and tool steels, tungsten-based materials, and forgings and
castings. Our specialty metals are produced in a wide range of alloys and product forms and are
selected for use in environments that demand metals having exceptional hardness, toughness,
strength, resistance to heat, corrosion or abrasion, or a combination of these characteristics.
We are
Building the Worlds Best Specialty Metals Company
by focusing our technological and
manufacturing capabilities to serve global end use markets with highly diversified and specialized
product offerings. Key end use markets for our products include:
Aerospace and Defense
. We are a world leader in the production of premium titanium alloys,
nickel-based and cobalt-based alloys and superalloys, and vacuum-melted specialty alloys used in
the manufacture of both commercial and military jet engines, as well as replacement parts for those
engines. We also produce titanium alloys, vacuum-melted specialty alloys, and high-strength
stainless alloys for use in commercial and military airframe components.
Titanium and titanium alloys are critical metals in aerospace and defense applications.
Titanium and titanium alloys possess an extraordinary combination of properties, including superior
strength-to-weight ratio, good elevated temperature resistance, low coefficient of thermal
expansion, and extreme corrosion resistance. These metals are used to produce jet engine
components such as blades, vanes, discs, and casings, and airframe components such as structural
members, landing gear, hydraulic systems, and fasteners. The latest and next-generation airframes
and jet engines use even more titanium and titanium alloys in component parts in order to minimize
weight and maximize fuel efficiency.
Our nickel-based alloys and superalloys and specialty alloys are also widely used in aerospace
and defense applications. Nickel-based alloys and superalloys remain extremely strong at high
temperatures and resist degradation under extreme conditions. Typical aerospace applications for
nickel-based alloys and superalloys include jet engine shafts, discs, blades, vanes, rings and
casings.
Our specialty alloys include vacuum-melted maraging steels used in the manufacture of aircraft
landing gear and structural components, as well as jet engine components.
We continuously seek to develop new alloys to better serve the needs of this end use market.
For example, we have developed ATI 425 titanium, a new cold-rollable alloy, as a lower cost
alternative to the most popular high-strength titanium alloys, for use in airframe components. We
have also developed Allvac® 718 Plus® alloy, a new nickel-based superalloy that can withstand
higher temperatures than the standard 718 superalloy, for use in the next generation of fuel
efficient jet engines. Demand for our products by the aerospace and defense market has increased
significantly over the last several years, and we expect it to remain strong and continue to grow
into the next decade.
Chemical Process Industry and Oil and Gas.
Oil and gas prices have reached record levels over
the past two years, resulting in increased global oil and gas exploration and development. The
environments in which oil and gas can be found in commercial quantities have become more
challenging, involving deep offshore wells, high pressure and temperature conditions, sour wells
and unconventional sources, such as oil sands. Sustained high oil and gas prices have also led to
increased interest in biofuels, such as ethanol, as an alternative to, or to supplement, gasoline
and other fossil fuels, and in liquefied natural gas (LNG).
3
All of our business segments produce metals that are critical to the chemical process industry
and oil and gas industry. Our specialty metals, including titanium and titanium alloys,
nickel-based alloys, stainless steel alloys and other specialty alloys, have the strength and
corrosion resistant properties necessary in the chemical process industry, and global demand for
these materials has been increasing, particularly in rapidly growing industrial markets in Asia.
We also provide advanced specialty metals used in offshore oil and gas production, including
offshore piping systems and subsea oil and gas fields.
We continuously seek to develop new alloys to better serve the needs of this end use market.
For example, we have developed AL 2003 lean duplex alloy as a low cost substitute for type 316L
stainless steel. AL 2003 lean duplex stainless, AL 2205 duplex stainless, and AL-6XN®
superaustenitic stainless steel in strip and plate product forms are NORSOK qualified. ATIs
titanium castings are also qualified under NORSOK standards. The NORSOK standards are developed by
the Norwegian petroleum industry and are intended to identify metals used in oil and gas
applications that are safe and cost effective.
Our specialty metals are used in the manufacturing and storage of biofuels, particularly
ethanol. Demand for our stainless and specialty alloys products for ethanol applications has
recently increased significantly and we expect demand to stay strong for the next several years.
Tungsten is the most dense and heat resistant metal commercially available. One application
for our tungsten products is oil and gas drill bit inserts. As drilling methods, including
directional drilling, become more complex, our advanced tungsten carbide and diamond matrix
materials are often utilized in order to enable faster drilling and longer drill bit life.
Electrical Energy
. Our specialty metals are widely used in the global electric power
generation and distribution industry. We believe that U.S. and European environmental policies and
the electrification of rapidly developing Asian countries will likely result in continuing strong
demand for our specialty metals products that we sell for use in this industry.
Coal-fired power plants account for more than one-half of the electricity produced in the
United States. Under the Clean Air Interstate Rule adopted by the U.S Environmental Protection
Agency (EPA), power plants in several eastern states will be required, in stages through 2015, to
dramatically reduce emissions of sulfur dioxide and nitrous oxide generated from the burning of
coal. Most of these plants will be required to install additional filtration systems, or
scrubbers, which are made of specialty metals we produce, on their smokestacks to comply with the
rule. Demand for our specialty metals for pollution control systems is also significant in growing
industrial economies, including China. We supply a broad range of alloys, including many
proprietary alloys, for these applications. AL-6XN® alloy, a 6-molybdenum super-austenitic alloy,
is used in absorber towers, piping, damper doors, ducting and vessels. The nickel-based AL 22 and
AL 276 alloys are used in the absorber inlet, absorber outlet ducting, damper door seals, and
expansion joints.
For electrical power generation, our specialty metals and corrosion resistant alloys (CRAs)
are used in coal, nuclear, natural gas, and wind power applications. In coal-fired plants, our
CRAs are used for pipe, tube, and heat exchanger applications in water systems in addition to the
pollution control scrubbers mentioned in the preceding paragraph. For nuclear power plants, we are
an industry pioneer in reactor-grade zirconium and hafnium alloys nuclear fuel cladding and
structural components. Our CRAs are also used in water systems for nuclear power plants. We are a
technology leader for large diameter nickel-based superalloys used in natural gas turbines. We are
one of a few producers of very large ductile iron castings used for wind turbines.
For electrical power distribution, our grain-oriented silicon electrical steel is used in
large and small power transformers, where electrical conductivity and magnetic properties are
important. We believe that demand for these advanced specialty metals is in the early stage of an
expected long growth cycle as developing countries, such as China and India, electrify and build
electrical power distribution grids.
Medical
. ATIs advanced specialty metals are used in medical device products that save and
enhance the quality of lives.
Our zirconium-niobium, titanium-and cobalt-based alloys are used for knees, hips and other
prosthetic devices. These replacement devices offer the potential of lasting much longer than
previous implant options.
Our biocompatible nickel-titanium shape memory alloy is used for stents to support collapsed
or clogged blood vessels. Reduced in diameter for insertion, these stents expand to the original
tube-like shape due to the metals superelasticity. Our ultra fine diameter (0.002 inch/0.051 mm)
titanium wire is used for screens to prevent blood
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clots from entering critical areas of the body. In addition, our titanium bar and wire are
used to make surgical screws for bone repairs.
Manufacturers of magnetic resonance imaging (MRI) devices rely on our niobium superconducting
wire to help produce electromagnetic fields that allow physicians to safely scan the bodys soft
tissue. In addition, our tungsten heavy alloy materials are used for shielding applications in MRI
devices.
Enhancing and Expanding Our Manufacturing Capabilities and Capacity.
Demand for our products
from the aerospace and defense, chemical process industry and oil and gas, electrical energy, and
medical markets has increased significantly over the last several years, and we expect demand to
remain strong and continue to grow into the next decade. We are currently undertaking a
multi-phase program to enhance and expand our capabilities and capacities to produce premium
specialty metals aimed at these key growth markets. Through 2009, we
intend to spend at least $925
million of internally generated funds to renew and expand our annual titanium sponge production
capabilities to approximately 44 million pounds; expand our premium titanium alloy melt and remelt
capacity; expand our nickel-based alloy and superalloy melt and remelt capacity; expand our
titanium and specialty alloy plate capacity; and expand our premium titanium and nickel-based
superalloy forging capacity. These investments strengthen ATIs leadership position in the
production of technically demanding specialty metals.
Business Segments
We operate in the following three business segments, which accounted for the following
percentages of total revenues of $4.9 billion, $3.5 billion, and $2.7 billion for the years ended
December 31, 2006, 2005, and 2004, respectively:
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2006
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2005
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2004
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High Performance Metals
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37
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%
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35
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%
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29
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Flat-Rolled Products
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54
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54
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60
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Engineered Products
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9
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11
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11
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High Performance Metals Segment
Our High Performance Metals segment produces, converts and distributes a wide range of high
performance alloys, including nickel- and cobalt-based alloys and superalloys, titanium and
titanium-based alloys, exotic metals such as zirconium, hafnium, niobium, nickel-titanium, and
their related alloys, and other specialty metals, primarily in long product forms such as ingot,
billet, bar, rod, wire, and seamless tube. We are integrated from raw materials (sponge) to
melt, remelt, and finish processing in our titanium and titanium alloy, and zirconium and hafnium
alloy products. The major end markets served by our High Performance Metals Segment are aerospace
and defense, chemical process industry, oil and gas, medical and electrical energy. Most of the
products in our High Performance Metals segment are sold directly to end-use customers. A
significant portion of our High Performance Metals segment products are sold under multi-year
agreements. The operating units in this segment are ATI Allvac, ATI Allvac Ltd (U.K.) and ATI Wah
Chang.
Flat-Rolled Products Segment
Our Flat-Rolled Products segment produces, converts and distributes stainless steel, nickel-based
alloys, and titanium and titanium-based alloys, in a variety of product forms, including plate,
sheet, engineered strip, and Precision Rolled Strip
®
products, as well as grain-oriented
silicon electrical steel, and tool steels. The major end markets for our flat-rolled products are
chemical process industry, oil and gas, electrical energy, automotive, food equipment and
appliances, machine and cutting tools, construction and mining, aerospace and defense, and
electronics, communication equipment and computers. The operations in this segment are ATI
Allegheny Ludlum, our 60% interest in the Chinese joint venture company known as Shanghai STAL
Precision Stainless Steel Company Limited (STAL), and our 50% interest in the industrial titanium
joint venture known as Uniti LLC. The remaining 40% interest in STAL is owned by the Baosteel
Group, a state authorized investment company whose equity securities are publicly traded in the
Peoples Republic of China. The remaining 50% interest in Uniti LLC is held by Verkhnaya Salda
Metallurgical Production Association (VSMPO), a Russian producer of titanium, aluminum, and
specialty steel products.
Stainless steel, nickel-based alloys and titanium sheet products are used in a wide variety of
industrial and consumer applications. In 2006, approximately 70% by volume of our sheet products
were sold to independent
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service centers, which have slitting, cutting or other processing facilities, with the
remainder sold directly to end-use customers.
Engineered
strip and very thin Precision Rolled
Strip
®
products are used by customers to
fabricate a variety of products primarily in the automotive, construction and electronics markets.
In 2006, approximately 90% by volume of our engineered strip and Precision Rolled Strip products
were sold directly to end-use customers or through our own distribution network, with the remainder
sold to independent service centers.
Stainless steel, nickel-based alloy and titanium plate products are primarily used in
industrial markets. In 2006, approximately 60% by volume of our plate products were sold to
independent service centers, with the remainder sold directly to end-use customers.
Grain-oriented silicon electrical steel is used in power transformers where electrical
conductivity and magnetic properties are important. Nearly all of our grain-oriented silicon
electrical steel products are sold directly to end-use customers.
Tool steels are used for hand tools and for cutting, shaping, forming, blanking, and drilling
of materials. Included in this category are our armor materials, which are designed to resist
penetration by ballistic projectiles and to resist blasts.
Engineered Products Segment
The principal business of our Engineered Products segment includes the production of tungsten
powder, tungsten heavy alloys, tungsten carbide materials and carbide cutting tools. We are now
integrated from the raw materials (ammonium paratungstate (APT)) to the manufacture of finished
cutting tools. The segment also produces carbon alloy steel impression die forgings, and large
grey and ductile iron castings, and provides precision metals processing services. The operating
units in this segment are ATI Metalworking Products, ATI Portland Forge, ATI Casting Service and
Rome Metals.
We produce a line of sintered tungsten carbide products that approach diamond hardness for
industrial markets including automotive, chemical process industry, oil and gas, machine and cutting
tools, aerospace, construction and mining, and other markets requiring tools with extra hardness. Technical
developments related to ceramics, coatings and other disciplines are incorporated in these
products. We also produce tungsten and tungsten carbide powders.
We forge carbon alloy steels into finished forms that are used primarily in the transportation
and construction equipment markets. We also cast grey and ductile iron metals used in the
transportation, wind power generation and automotive markets. We have precision metals processing
capabilities that enable us to provide process services for most high-value metals from ingots to
finished product forms. Such services include grinding, polishing, blasting, cutting, flattening,
and ultrasonic testing.
Competition
Markets for our products and services in each of our three business segments are highly
competitive. We compete with many producers and distributors who, depending on the product
involved, range from large diversified enterprises to smaller companies specializing in particular
products. Factors that affect our competitive position are the quality of our products, services
and delivery capabilities, our capabilities to produce a wide range of specialty materials in
various alloys and product forms, our technological capabilities including our research and
development efforts, our marketing strategies, the prices for our products and services, our
manufacturing costs, and industry manufacturing capacity.
We face competition from both domestic and foreign companies, some of which are government
subsidized. In 1999, the United States imposed antidumping and countervailing duties on dumped and
subsidized imports of stainless steel sheet and strip in coils and stainless steel plate in coils
from companies in ten foreign countries. These duties were reviewed by the U.S. Commerce Department
and the U.S. International Trade Commission in 2005 and generally remain in effect. We continue to
monitor unfairly traded imports from foreign producers for appropriate action.
6
High Performance Metals segment Major Competitors
Nickel-based alloys and superalloys and specialty steel alloys
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Carpenter Technology Corporation
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Special Metals Corporation, a PCC company
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ThyssenKrupp VDM GmbH, a company of ThyssenKrupp Stainless (Germany)
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Titanium and titanium-based alloys
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Titanium Metals Corporation
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RMI Titanium, an RTI International Metals Company
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VSMPO AVISMA (Russia)
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Exotic alloys
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Cezus, a group member of AREVA (France)
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HC Stark
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Western Zirconium Plant of Westinghouse Electric Company, owned by Toshiba Corporation
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Flat-Rolled Products segment Major Competitors
Stainless steel
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AK Steel Corporation
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North American Stainless (NAS), owned by Acerinox S.A. (Spain)
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Outokumpu Stainless Plate Products, owned by Outokumpu Oyj (Finland)
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Imports from
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Arcelor Mittal (France, Belgium and Germany)
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Mexinox S.A. de C.V., group member of ThyssenKrupp AG
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ThyssenKrupp AG (Germany)
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Ta Chen International Corporation (Taiwan)
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Various Chinese producers
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Engineered Products segment Major Competitors
Tungsten and tungsten carbide products
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Kennametal Inc.
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Iscar (Israel)
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Sandvik AB (Sweden)
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Seco Tools AB (Sweden), owned by Sandvik A.B.
|
7
Raw Materials and Supplies
Substantially all raw materials and supplies required in the manufacture of our products are
available from more than one supplier and the sources and availability of raw materials essential
to our businesses are adequate. The principal raw materials we use in the production of our
specialty metals are scrap (including iron-, nickel-, chromium-, titanium-, molybdenum-, and
tungsten-bearing scrap), nickel, titanium sponge, zirconium sand and sponge, ferrochromium,
ferrosilicon, molybdenum and molybdenum alloys, ammonium paratungstate, manganese and manganese
alloys, cobalt, niobium, vanadium and other alloying materials.
Purchase prices of certain principal raw materials have been volatile. As a result, our
operating results may be subject to significant fluctuation. We use raw materials surcharge and
index mechanisms to offset the impact of increased raw material costs; however, competitive factors
in the marketplace may limit our ability to institute such mechanisms, and there can be a delay
between the increase in the price of raw materials and the realization of the benefit of such
mechanisms. For example, since we generally use in excess of 85 million pounds of nickel each year,
a hypothetical increase of $1.00 per pound in nickel prices would result in increased costs of
approximately $85 million. We also use in excess of 800 million pounds of ferrous scrap annually in
the production of our flat-rolled products so that a hypothetical increase of $0.01 per pound in
ferrous scrap prices would result in increased costs of approximately $8 million.
While we are increasing our manufacturing capacity to produce titanium sponge, the major raw
material for our titanium products, a portion of our needs, together with certain other raw
materials, such as nickel, cobalt, and ferrochromium, are available to us and our specialty metals
industry competitors primarily from foreign sources. Some of these foreign sources are located in
countries that may be subject to unstable political and economic conditions, which might disrupt
supplies or affect the price of these materials.
We purchase our nickel requirements principally from producers in Australia, Canada, Norway,
Russia, and the Dominican Republic. Zirconium sponge is purchased from a source in France, while
zirconium sand is purchased from both U.S. and Australian sources. Cobalt is purchased primarily
from producers in Canada. More than 80% of the worlds reserves of ferrochromium are located in
South Africa, Zimbabwe, Albania, and Kazakhstan. We also purchase titanium sponge from sources in
Kazakhstan, Japan, and Russia.
Export Sales and Foreign Operations
Direct international sales represented approximately 24% of our total annual sales in 2006, 25% of
our total sales in 2005, and approximately 20% of our total sales in 2004. These figures include
direct export sales by our U.S.-based operations to customers in foreign countries, which accounted
for approximately 16% of our total sales in each of 2006 and 2005, and 12% of our total sales in
2004. Our overseas sales, marketing and distribution efforts are aided by our international
marketing and distribution offices, ATI Europe, ATI Europe Distribution, and ATI Asia, or by
independent representatives located at various locations throughout the world.
In 2006, our sales in the United States and Canada represented 76% and 3%, respectively, of
total 2006 sales. Within Europe, our sales to the United Kingdom, Germany, and France represented
4%, 3% and 3%, respectively, of total 2006 sales. Within Asia, our 2006 sales to China and Japan
represented 4% and 1%, respectively, of total sales.
Our Allvac Ltd business has manufacturing capabilities in the United Kingdom. Our Metalworking
Products business, which has manufacturing capabilities in the United Kingdom and Switzerland,
sells high precision threading, milling, boring and drilling components, tungsten carbide burrs,
rotary tooling and specialty abrasive wheels and discs for the European market from locations in
the United Kingdom, Switzerland, Germany, France, Italy and Spain. Our STAL joint venture in the
Peoples Republic of China produces Precision Rolled Strip products, which enables us to offer
these products more effectively to markets in China and other Asian countries. Our Uniti LLC joint
venture allows us to offer titanium products to industrial markets more effectively worldwide.
Backlog, Seasonality and Cyclicality
Our backlog of confirmed orders was approximately $1.2 billion at December 31, 2006 and $1.0
billion at December 31, 2005. We expect that approximately 92% of confirmed orders on hand at
December 31, 2006 will be filled during the year ending December 31, 2007. Backlog of confirmed
orders of our High Performance Metals segment was approximately $730 million at December 31, 2006
and $615 million at December 31, 2005. We expect
8
that approximately 86% of the confirmed orders on hand at December 31, 2006 for this segment will
be filled during the year ending December 31, 2007. Backlog of confirmed orders of our Flat-Rolled
Products segment was approximately $353 million at December 31, 2006 and $245 million at December
31, 2005. We expect that all of the confirmed orders on hand at December 31, 2006 for this segment
will be filled during the year ending December 31, 2007.
Generally, our sales and operations are not seasonal. However, demand for our products is
cyclical over longer periods because specialty metals customers operate in cyclical industries and
are subject to changes in general economic conditions and other factors both external and internal
to those industries.
Research, Development and Technical Services
We believe that our research and development capabilities give ATI an advantage in developing new
products and manufacturing processes that contribute to the profitable growth potential of our
businesses on a long-term basis. We conduct research and development at our various operating
locations both for our own account and, on a limited basis, for customers on a contract basis.
Research and development expenditures for each of our three segments for the years ended December
31, 2006, 2005, and 2004 included the following:
|
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|
|
|
|
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|
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|
|
(In millions)
|
|
2006
|
|
2005
|
|
2004
|
|
|
|
Company-Funded:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
High Performance Metals
|
|
$
|
5.9
|
|
|
$
|
4.9
|
|
|
$
|
4.7
|
|
|
Flat-Rolled Products
|
|
|
1.5
|
|
|
|
1.4
|
|
|
|
1.6
|
|
|
Engineered Products
|
|
|
2.2
|
|
|
|
2.1
|
|
|
|
1.9
|
|
|
|
|
|
|
$
|
9.6
|
|
|
$
|
8.4
|
|
|
$
|
8.2
|
|
|
|
|
Customer-Funded:
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|
|
|
|
|
|
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High Performance Metals
|
|
$
|
0.2
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|
|
$
|
1.5
|
|
|
$
|
1.3
|
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|
Flat-Rolled Products
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0.3
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0.2
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|
0.4
|
|
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|
|
|
|
$
|
0.5
|
|
|
$
|
1.7
|
|
|
$
|
1.7
|
|
|
|
|
|
|
|
|
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|
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|
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|
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Total Research and Development
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$
|
10.1
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|
|
$
|
10.1
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|
|
$
|
9.9
|
|
|
|
Our research,
development and technical service activities are closely interrelated and are directed toward cost
reduction and process improvement, process control, quality assurance and control, system
development, the development of new manufacturing methods, the improvement of existing
manufacturing methods, the improvement of existing products, and the development of new products.
We
own hundreds of United States patents, many of which are also filed under the patent
laws of other nations. Although these patents, as well as our numerous trademarks, technical
information, license agreements, and other intellectual property, have been and are expected to be
of value, we believe that the loss of any single such item or technically related group of such
items would not materially affect the conduct of our business.
Environmental, Health and Safety Matters
We are subject to various domestic and international environmental laws and regulations that govern
the discharge of pollutants, and disposal of wastes, and which may require that we investigate and
remediate the effects of the release or disposal of materials at sites associated with past and
present operations. We could incur substantial cleanup costs, fines, civil or criminal sanctions,
third party property damage or personal injury claims as a result of violations or liabilities
under these laws or non-compliance with environmental permits required at our facilities. We are
currently involved in the investigation and remediation of a number of our current and former sites
as well as third party sites.
We consider environmental compliance to be an integral part of our operations. Environmental
compliance and protection is addressed in our
Corporate Guidelines for Business Conduct and Ethics
and separate Environmental Guidelines that require compliance with all federal, state, regional and
local environmental laws and regulations. Each operating company has an environmental management
system that includes mechanisms for regularly evaluating environmental compliance and managing
changes in business operations while assessing environmental impact.
9
Our
Corporate Guidelines for Business Conduct and Ethics
also address compliance with employment
and workplace safety laws, and describe our commitment to equal opportunity and fair treatment of
employees.
Employees
We have approximately 9,500 full-time employees. A portion of our workforce is covered by various
collective bargaining agreements, principally with the United Steel, Paper and Forestry, Rubber,
Manufacturing, Energy, Allied Industrial and Service Workers International Union (USW),
including: approximately 2,800 Allegheny Ludlum production, office and maintenance employees
covered by collective bargaining agreements that are effective through June 2007, approximately 340
Allvac Albany, Oregon (Oremet) employees covered by a collective bargaining agreement that is
effective through June 2007, approximately 600 Wah Chang employees covered by a collective
bargaining agreement that continues through March 2008, approximately 270 employees at our Casting
Service facility in LaPorte, Indiana, covered by a collective bargaining agreement that is
effective through December 2007, and approximately 200 employees at our Portland Forge facility in
Portland, Indiana, covered by collective bargaining agreements with three unions that are effective
through April 2008. In February 2007, we announced that the USW and Allegheny Ludlum and Allvacs
Albany, Oregon titanium operations had reached tentative four-year collective bargaining
agreements, subject to ratification by the union membership. If ratified, the new agreements will
expire on June 30, 2011.
Available Information
Our Internet website address is http://www.alleghenytechnologies.com. Our annual reports on Form
10-K, quarterly reports on Form 10-Q, current reports on Form 8-K and amendments to those reports
filed or furnished pursuant to Section 13(a) or 15(d) of the Securities Exchange Act of 1934, as
well as proxy and information statements and other information that we file, are available free of
charge through our Internet website as soon as reasonably practicable after we electronically file
such material with, or furnish such material to, the United States Securities and Exchange
Commission. Our Internet website and the content contained therein or connected thereto are not
intended to be incorporated into this Annual Report on Form 10-K. You may read and copy materials
we file with the SEC at the SECs Public Reference Room at 100 F Street, NE, Washington, DC 20549.
You may obtain information on the operation of the Public Reference Room by calling the SEC at
1-800-SEC-0330. The SEC maintains an Internet website at http://www.sec.gov which contains reports,
proxy and information statements and other information that we file electronically with the SEC.
Principal Executive Officers of the Registrant*
Principal executive officers of the Company as of February 14, 2007 are as follows:
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|
|
|
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Name
|
|
Age
|
|
Title
|
|
L. Patrick Hassey
|
|
|
61
|
|
|
Chairman, President and Chief Executive Officer and Director
|
|
Richard J. Harshman
|
|
|
50
|
|
|
Executive Vice President, Finance and Chief Financial Officer
|
|
Douglas A. Kittenbrink
|
|
|
51
|
|
|
Executive Vice President, ATI Business System and Group
President, Engineered Products Segment
|
|
Jack W. Shilling
|
|
|
63
|
|
|
Executive Vice President, Corporate Development and Chief
Technical Officer
|
|
Jon D. Walton
|
|
|
64
|
|
|
Executive Vice President, Human Resources, Chief Legal and
Compliance Officer, General Counsel and Corporate Secretary
|
|
Dale G. Reid
|
|
|
51
|
|
|
Vice President, Controller, Chief Accounting Officer and Treasurer
|
|
|
|
|
|
*
|
|
Such officers are subject to the reporting and other requirements of Section 16 of the
Securities Exchange Act of 1934, as amended.
|
10
Set forth below are descriptions of the business background for the past five years of the
principal officers of the Company.
L
.
Patrick Hassey
has been President and Chief Executive Officer since October 1, 2003. He was
elected to the Companys Board of Directors in July 2003 and has served as Chairman since May 2004.
Prior to this position, he worked as an outside management consultant to Allegheny Technologies
executive management team. Mr. Hassey was Executive Vice President and a member of the corporate
executive committee of Alcoa, Inc. at the time of his early retirement in February 2003. He had
served as Executive Vice President of Alcoa and Group President of Alcoa Industrial Components from
May 2000 to October 2002. Prior to May 2000, he served as Executive Vice President of Alcoa and
President of Alcoa Europe, Inc.
Richard J. Harshman
has served as Executive Vice President, Finance since October 2003 and
Chief Financial Officer since December 2000. Mr. Harshman was Senior Vice President, Finance from
December 2001 to October 2003 and Vice President, Finance from December 2000 to December 2001.
Previously, he had served in a number of financial management roles for Allegheny Technologies
Incorporated and Teledyne, Inc.
Douglas A. Kittenbrink
has served as Executive Vice President, ATI Business System and Group
President, Engineered Products Segment since October 2003. Mr. Kittenbrink was Executive Vice
President and Chief Operating Officer from July 2001 to October 2003 and served as President of
Allegheny Ludlum from April 2000 to November 2002. Effective March 1, 2007, he will serve as
Executive Vice President, Corporate Planning and International Business Development.
Jack W. Shilling
has served as Executive Vice President, Corporate Development and Chief
Technical Officer since October 2003. Dr. Shilling was Executive Vice President, Strategic
Initiatives and Technology and Chief Technology Officer from July 2001 to October 2003. He served
as President of the High Performance Metals Segment from April 2000 to July 2001. Dr. Shilling has
announced his retirement, effective March 31, 2007.
Jon D. Walton
has been Executive Vice President, Human Resources, Chief Legal and Compliance
Officer, General Counsel and Corporate Secretary since October 2003. Mr. Walton was Senior Vice
President, Chief Legal and Administrative Officer from July 2001 to October 2003. Previously, he
was Senior Vice President, General Counsel and Secretary.
Dale G. Reid
has served as Vice President, Controller, Chief Accounting Officer and Treasurer
since December 2003. Mr. Reid was Vice President, Controller and Chief Accounting Officer from
December 2000 through November 2003.
Item 1A. Risk Factors
There are inherent risks and uncertainties associated with our business that could adversely affect
our operating performance and financial condition. Set forth below are descriptions of those risks
and uncertainties that we currently believe to be material, but the risks and uncertainties
described are not the only risks and uncertainties that could affect our business. See the
discussion under Forward Looking Statements in Item 7, Managements Discussion and Analysis of
Financial Condition and Results of Operations, in this Annual Report on Form 10-K.
Cyclical Demand for Products.
The cyclical nature of the industries in which our customers
operate causes demand for our products to be cyclical, creating uncertainty regarding future
profitability. Various changes in general economic conditions affect the industries in which our
customers operate. These changes include decreases in the rate of consumption or use of our
customers products due to economic downturns. Other factors causing fluctuation in our customers
positions are changes in market demand, lower overall pricing due to domestic and international
overcapacity, currency fluctuations, lower priced imports and increases in use or decreases in
prices of substitute materials. As a result of these factors, our profitability has been and may in
the future be subject to significant fluctuation.
Product Pricing.
From time-to-time, intense competition and excess manufacturing capacity have
resulted in reduced prices, excluding raw material surcharges, for many of our products. These
factors have had and may have an adverse impact on our revenues, operating results and financial
condition.
11
Although inflationary trends in recent years have been moderate, during the same period
certain critical raw material costs, such as nickel and titanium sponge, and scrap containing iron,
nickel, and titanium have been volatile and at historically high levels. While we are able to
mitigate some of the adverse impact of rising raw material costs through raw material surcharges or
indices to customers, rapid increases in raw material costs may adversely affect our results of
operations.
We change prices on certain of our products from time-to-time. The ability to implement price
increases is dependent on market conditions, economic factors, raw material costs and availability,
competitive factors, operating costs and other factors, some of which are beyond our control. The
benefits of any price increases may be delayed due to long manufacturing lead times and the terms
of existing contracts.
Risks Associated with Commercial Aerospace.
A significant portion of the sales of our High
Performance Metals segment represents products sold to customers in the commercial aerospace
industry. The commercial aerospace industry has historically been cyclical due to factors both
external and internal to the airline industry. These factors include general economic conditions,
airline profitability, consumer demand for air travel, varying fuel and labor costs, price
competition, and international and domestic political conditions such as military conflict and the
threat of terrorism. The length and degree of cyclical fluctuation are influenced by these factors
and therefore are difficult to predict with certainty. Demand for our products in this segment is
subject to these cyclical trends. For example, the average price per pound for our titanium mill
products was $11.89 for the period 2002 through 2004, was $22.75 in 2005, and was $33.83 in 2006,
and the average price per pound for our nickel-based and specialty alloys was $7.19 for the period
2002 through 2004, was $11.25 in 2005, and was $14.35 in 2006. A downturn in the commercial
aerospace industry would adversely affect the prices at which we are able to sell these and other
products, and our results of operations, business and financial condition could be materially
adversely affected.
Risks Associated with Strategic Capital Projects.
From time-to-time, we undertake strategic
capital projects in order to expand and upgrade our facilities and operational capabilities. For
instance, in 2005 and 2006 we announced major expansions of our titanium and premium-melt
nickel-based alloy, superalloy and specialty alloy production capabilities. Our ability to achieve
the anticipated increased revenues or otherwise realize acceptable returns on these investments or
other strategic capital projects that we may undertake is subject to a number of risks, many of
which are beyond our control, including a variety of market, operational, permitting, and labor
related factors. In addition, the cost to implement any given strategic capital project ultimately
may prove to be greater than originally anticipated. If we are not able to achieve the anticipated
results from the implementation of any of our strategic capital projects, or if we incur
unanticipated implementation costs, our results of operations and financial position may be
materially adversely effected.
Dependence on Critical Raw Materials Subject to Price and Availability Fluctuations.
We rely
to a substantial extent on third parties to supply certain raw materials that are critical to the
manufacture of our products. Purchase prices and availability of these critical raw materials are
subject to volatility. At any given time we may be unable to obtain an adequate supply of these
critical raw materials on a timely basis, on price and other terms acceptable, or at all.
If suppliers increase the price of critical raw materials, we may not have alternative sources
of supply. In addition, to the extent that we have quoted prices to customers and accepted customer
orders for products prior to purchasing necessary raw materials, or have existing contracts, we may
be unable to raise the price of products to cover all or part of the increased cost of the raw
materials.
The manufacture of some of our products is a complex process and requires long lead times. As
a result, we may experience delays or shortages in the supply of raw materials. If unable to obtain
adequate and timely deliveries of required raw materials, we may be unable to timely manufacture
sufficient quantities of products. This could cause us to lose sales, incur additional costs, delay
new product introductions, or suffer harm to our reputation.
We acquire certain important raw materials that we use to produce specialty materials,
including nickel, chromium, cobalt, and titanium sponge, from foreign sources. Some of these
sources operate in countries that may be subject to unstable political and economic conditions.
These conditions may disrupt supplies or affect the prices of these materials.
12
Volatility of Raw Material Costs.
The prices for many of the raw materials we use have been
extremely volatile. Since we value most of our inventory utilizing the last-in, first-out (LIFO)
inventory costing methodology, a rapid rise in raw material costs has a negative effect on our
operating results. Under the LIFO inventory valuation method, changes in the cost of raw materials
and production activities are recognized in cost of sales in the current period even though these
material and other costs may have been incurred at significantly different values due to the length
of time of our production cycle. For example, in 2006, the increase in raw material costs on the
LIFO inventory valuation method resulted in cost of sales which was $197.0 million higher than
would have been recognized if we utilized the first-in, first-out (FIFO) methodology to value our
inventory. In a period of rising raw material prices, cost of sales expense recognized under LIFO
is generally higher than the cash costs incurred to acquire the inventory sold. Conversely, in a
period of declining raw material prices, cost of sales recognized under LIFO is generally lower
than cash costs incurred to acquire the inventory sold.
Availability of Energy Resources.
We rely upon third parties for our supply of energy
resources consumed in the manufacture of our products. The prices for and availability of
electricity, natural gas, oil and other energy resources are subject to volatile market conditions.
These market conditions often are affected by political and economic factors beyond our control.
Disruptions in the supply of energy resources could temporarily impair the ability to manufacture
products for customers. Further, increases in energy costs, or changes in costs relative to energy
costs paid by competitors, has and may continue to adversely affect our profitability. To the
extent that these uncertainties cause suppliers and customers to be more cost sensitive, increased
energy prices may have an adverse effect on our results of operations and financial condition.
Risks Associated with Environmental Matters.
We are subject to various domestic and
international environmental laws and regulations that govern the discharge of pollutants, and
disposal of wastes, and which may require that we investigate and remediate the effects of the
release or disposal of materials at sites associated with past and present operations. We could
incur substantial cleanup costs, fines and civil or criminal sanctions, third party property damage
or personal injury claims as a result of violations or liabilities under these laws or
non-compliance with environmental permits required at our facilities. We are currently involved in
the investigation and remediation of a number of our current and former sites as well as third
party sites.
With respect to proceedings brought under the federal Superfund laws, or similar state
statutes, we have been identified as a potentially responsible party (PRP) at approximately 28 of
such sites, excluding those at which we believe we have no future liability. Our involvement is
limited or de minimis at approximately 21 of these sites, and the potential loss exposure with
respect to any of the remaining seven individual sites is not considered to be material.
We are a party to various cost-sharing arrangements with other PRPs at the sites. The terms of
the cost-sharing arrangements are subject to non-disclosure agreements as confidential information.
Nevertheless, the cost-sharing arrangements generally require all PRPs to post financial assurance
of the performance of the obligations or to pre-pay into an escrow or trust account their share of
anticipated site-related costs. In addition, the Federal government, through various agencies, is a
party to several such arrangements.
We believe that we operate our businesses in compliance in all material respects with
applicable environmental laws and regulations. However, from time-to-time, we are a party to
lawsuits and other proceedings involving alleged violations of, or liabilities arising from
environmental laws. When our liability is probable and we can reasonably estimate our costs, we
record environmental liabilities in our financial statements. In many cases, we are not able to
determine whether we are liable, or if liability is probable, to reasonably estimate the loss or
range of loss. Estimates of our liability remain subject to additional uncertainties, including the
nature and extent of site contamination, available remediation alternatives, the extent of
corrective actions that may be required, and the participation number and financial condition of
other PRPs, as well as the extent of their responsibility for the remediation. We intend to adjust
our accruals to reflect new information as appropriate. Future adjustments could have a material
adverse effect on our results of operations in a given period, but we cannot reliably predict the
amounts of such future adjustments. At December 31, 2006, our reserves for environmental matters
totaled approximately $25 million. Based on currently available information, we do not believe that
there is a reasonable possibility that a loss exceeding the amount already accrued for any of the
sites with which we are currently associated (either individually or in the aggregate) will be an
amount that would be material to a decision to buy or
13
sell our securities. Future developments, administrative actions or liabilities relating to
environmental matters, however, could have a material adverse effect on our financial condition or
results of operations.
Risks Associated with Current or Future Litigation and Claims.
A number of lawsuits, claims
and proceedings have been or may be asserted against us relating to the conduct of our currently
and formerly owned businesses, including those pertaining to product liability, patent
infringement, commercial, employment, employee benefits, taxes, environmental, health and safety
and occupational disease, and stockholder matters. Due to the uncertainties of litigation, we can
give no assurance that we will prevail on all claims made against us in the lawsuits that we
currently face or that additional claims will not be made against us in the future. While the
outcome of litigation cannot be predicted with certainty, and some of these lawsuits, claims or
proceedings may be determined adversely to us, we do not believe that the disposition of any such
pending matters is likely to have a material adverse effect on our financial condition or
liquidity, although the resolution in any reporting period of one or more of these matters could
have a material adverse effect on our results of operations for that period. Also, we can give no
assurance that any other matters brought in the future will not have a material effect on our
financial condition, liquidity or results of operations.
Labor Matters.
We have approximately 9,500 full-time employees. A portion of our workforce is
covered by various collective bargaining agreements, principally with the USW, including:
approximately 2,800 Allegheny Ludlum production, office and maintenance employees covered by
collective bargaining agreements, which are effective through June 2007; approximately 340 Allvac
Albany, Oregon (Oremet) employees covered by a collective bargaining agreement, which is effective
through June 2007; approximately 600 Wah Chang employees covered by a collective bargaining
agreement, which continues through March 2008, approximately 270 employees at the Casting Service
facility in LaPorte, Indiana, covered by a collective bargaining agreement, which is effective
through December 2007, and approximately 200 employees at our Portland Forge facility in Portland,
Indiana, covered by collective bargaining agreements with three unions that are effective through
April 2008. In February 2007, we announced that the USW and Allegheny Ludlum and Allvacs Albany,
Oregon titanium operations had reached tentative four-year collective bargaining agreements,
subject to ratification by the union membership. If ratified, the new agreements will expire on
June 30, 2011.
Generally, collective bargaining agreements that expire may be terminated after notice by the
union. After termination, the union may authorize a strike. A strike by the employees covered by
one or more of the collective bargaining agreements could have a materially adverse affect on our
operating results. There can be no assurance that we will succeed in concluding collective
bargaining agreements with the unions to replace those that expire.
Risks Associated with Retirement Benefits.
Our U.S. qualified defined benefit pension plan was
funded in accordance with the requirements of the Employee Retirement Income Security Act of 1974
(ERISA), and the Internal Revenue Code, as of December 31, 2006. Based upon current actuarial
analyses and forecasts, we do not expect to be required to make contributions to the defined
benefit pension plan for at least the next several years. However, a significant decline in the
value of plan investments in the future or unfavorable changes in laws or regulations that govern
pension plan funding could materially change the timing and amount of required pension funding.
Depending on the timing and amount, a requirement that we fund our defined benefit pension plan
could have a material adverse effect on our results of operations and financial condition.
Risks Associated with Acquisition and Disposition Strategies.
We intend to continue to
strategically position our businesses in order to improve our ability to compete. We plan to do
this by seeking specialty niches, expanding our global presence, acquiring businesses complementary
to existing strengths and continually evaluating the performance and strategic fit of existing
business units. From time-to-time, management holds discussions with management of other companies
to explore acquisition, joint ventures, and other business combination opportunities as well as
possible business unit dispositions. As a result, the relative makeup of the businesses comprising
our Company is subject to change. Acquisitions, joint ventures, and other business combinations
involve various inherent risks, such as: assessing accurately the value, strengths, weaknesses,
contingent and other liabilities and potential profitability of acquisition or other transaction
candidates; the potential loss of key personnel of an acquired business; our ability to achieve
identified financial and operating synergies anticipated to result from an acquisition or other
transaction; and unanticipated changes in business and economic conditions affecting an acquisition
or other transaction. International acquisitions and other transactions could be affected by export
14
controls, exchange rate fluctuations, domestic and foreign political conditions and a
deterioration in domestic and foreign economic conditions.
Internal Controls Over Financial Reporting.
Because of its inherent limitations, internal
control over financial reporting may not prevent or detect misstatements. Also, projections of any
evaluation of effectiveness to future periods are subject to the risk that controls may become
inadequate because of changes in conditions, or that the degree of compliance with the policies or
procedures may deteriorate.
Insurance.
We have maintained various forms of insurance, including insurance covering claims
related to our properties and risks associated with our operations. Our existing property and
liability insurance coverages contain exclusions and limitations on coverage. From time-to-time, in
connection with renewals of insurance, we have experienced additional exclusions and limitations on
coverage, larger self-insured retentions and deductibles and significantly higher premiums. As a
result, in the future our insurance coverage may not cover claims to the extent that it has in the
past and the costs that we incur to procure insurance may increase significantly, either of which
could have an adverse effect on our results of operations.
Political and Social Turmoil.
The war on terrorism and recent political and social turmoil,
including terrorist and military actions and the implications of the military actions in Iraq,
could put pressure on economic conditions in the United States and worldwide. These political,
social and economic conditions could make it difficult for us, our suppliers and our customers to
forecast accurately and plan future business activities, and could adversely affect the financial
condition of our suppliers and customers and affect customer decisions as to the amount and timing
of purchases from us. As a result, our business, financial condition and results of operations
could be materially adversely affected.
Export Sales.
We believe that export sales will continue to account for a significant
percentage of our future revenues. Risks associated with export sales include: political and
economic instability, including weak conditions in the worlds economies; accounts receivable
collection; export controls; changes in legal and regulatory requirements; policy changes affecting
the markets for our products; changes in tax laws and tariffs; and exchange rate fluctuations
(which may affect sales to international customers and the value of profits earned on export sales
when converted into dollars). Any of these factors could materially adversely effect our results
for the period in which they occur.
Risks Associated with Government Contracts.
Some of our operating companies directly perform
contractual work for the U.S. Government. Various claims (whether based on U.S. Government or
Company audits and investigations or otherwise) could be asserted against us related to our U.S.
Government contract work. Depending on the circumstances and the outcome, such proceedings could
result in fines, penalties, compensatory and treble damages or the cancellation or suspension of
payments under one or more U.S. Government contracts. Under government regulations, a company, or
one or more of its operating divisions or units, can also be suspended or debarred from government
contracts based on the results of investigations.
Item 1B. Unresolved Staff Comments
None.
Item 2. Properties
Our principal domestic melting facilities for our high performance metals are located in Monroe,
NC, Bakers, NC, and Lockport, NY (vacuum induction melting, vacuum arc re-melt, electro-slag
re-melt, plasma melting); Richland, WA (electron beam melting); and Albany, OR (vacuum arc
re-melt). Production of high performance metals, most of which are in long product form, takes
place at our domestic facilities in Monroe, NC, Lockport, NY, Richburg, SC, and Albany, OR. In
2006, we announced plans to design and construct a new greenfield titanium sponge facility in
Rowley, UT. Construction of this facility is expected to begin in the first half of 2007 and is
expected to be completed in early 2009. Our production of exotic alloys takes place at facilities
located in Albany, OR, Huntsville, AL and Frackville, PA.
15
Our principal domestic locations for melting stainless steel and other flat-rolled specialty
metals are located in Brackenridge, Midland, Natrona and Latrobe, PA. Hot rolling of material is
performed at our domestic facilities in Brackenridge, Washington and Houston, PA. Finishing of our
flat-rolled products takes place at our domestic facilities located in Brackenridge, Bagdad,
Vandergrift, Midland and Washington, PA, and in Wallingford and Waterbury, CT, New Castle, IN, New
Bedford, MA, and Louisville, OH.
Our principal domestic facilities for the production of our engineered products are located in
Nashville, TN, Huntsville, Grant and Gurley, AL, Houston, TX, and Waynesboro, PA (tungsten powder,
tungsten carbide materials and carbide cutting tools and threading systems). Other domestic
facilities in this segment are located in Portland, IN and Lebanon, KY (carbon alloy steel
forgings); LaPorte, IN (grey and ductile iron castings); and southwestern Pennsylvania (precision
metals conversion services).
Substantially all of our properties are owned, and four of our properties are subject to
mortgages or similar encumbrances securing borrowings under certain industrial development
authority financings.
We also own or lease facilities in a number of foreign countries, including France, Germany,
Switzerland, United Kingdom, and the Peoples Republic of China. We own and/or lease and operate
facilities for melting and re-melting, machining and bar mill operations, laboratories and offices
located in Sheffield, England. Through our STAL joint venture, we operate a facility for finishing
Precision Rolled Strip products in the Xin-Zhuang Industrial Zone, Shanghai, China.
Our executive offices, located in PPG Place in Pittsburgh, PA are leased.
Although our facilities vary in terms of age and condition, we believe that they have been
well maintained and are in sufficient condition for us to carry on our activities.
Item 3. Legal Proceedings
In a letter dated May 20, 2004, the EPA informed a subsidiary of the Company that it alleges that
the company and forty other potentially responsible parties (PRPs) are not in compliance with the
Unilateral Administrative Order (UAO) issued to the company and the PRPs for the South El Monte
Operable Unit of the San Gabriel Valley (California) Superfund Site, a multi-part area-wide
groundwater cleanup. The EPA indicated that it may take action to enforce the UAO and collect
penalties, as well as reimbursement of the EPAs costs associated with the site. The PRPs are in
mediation with the EPA to resolve their obligations under the UAO on both technical and legal
grounds, and enforcement of the UAO has been stayed.
By letter dated November 29, 2005, the Pennsylvania Department of Environmental Protection
(DEP) alleged that Allegheny Ludlum Corporation, a subsidiary of the Company, was in violation of
the Pennsylvania Solid Waste Management Act (SWMA) and the rules and regulations promulgated
thereunder. DEP sought a civil penalty of $149,950. This matter was resolved for $75,000.
In 2005, the Allegheny County, Pennsylvania Health Department (ACHD) issued six Statements of
Violation to Allegheny Ludlum, alleging that Allegheny Ludlum violated various local air emission
regulations. Allegheny Ludlum denied the ACHDs allegations that it violated the various air
emission regulations and filed a timely appeal of the first Statement of Violation. Allegheny
Ludlum and the ACHD entered into a consent order and agreement wherein Allegheny Ludlum paid a
civil penalty and performed a supplemental environmental project.
By letter dated November 13, 2006, the DEP notified Allegheny Ludlum that it intended to
assess a civil penalty of $125,000 for alleged violations of the Clean Streams Law of Pennsylvania.
DEP alleges that Allegheny Ludlum discharged oil-bearing wastewaters causing a sheen upon waters
of the Commonwealth. Allegheny Ludlum denies the allegations and has been negotiating a resolution
of this matter with the DEP.
We become involved from time-to-time in various lawsuits, claims and proceedings relating to
the conduct of our current and formerly owned businesses, including those pertaining to product
liability, patent infringement, commercial, employment, employee benefits, taxes, environmental,
health and safety and occupational disease, and stockholder matters. While we cannot predict the
outcome of any lawsuit, claim or proceeding, our management
16
believes that the disposition of any pending matters is not likely to have a material adverse
effect on our financial condition or liquidity. The resolution in any reporting period of one or
more of these matters, however, could have a material adverse effect on our results of operations
for that period.
Information
relating to legal proceedings is included in Note 14. Commitments and
Contingencies of the Notes to Consolidated Financial Statements and incorporated herein by
reference.
Item 4. Submission of Matters to a Vote of Security Holders
Not applicable.
PART II
Item 5. Market for the Registrants Common Equity and Related Stockholder Matters
Common Stock Prices
Our common stock is traded on the New York Stock Exchange (symbol ATI). At February 14, 2007, there
were approximately 5,972 record holders of Allegheny Technologies Incorporated common stock. We
increased our quarterly cash dividends per share by over 100% since 2004. We paid a quarterly cash
dividend of $0.06 per share for each of the first three quarters of 2005. In the fourth quarter of
2005, we increased the quarterly cash dividend paid on our common stock to $0.10 per share. We
paid a quarterly cash dividend of $0.10 per share for each of the first three quarters of 2006, and in the
fourth quarter of 2006, we increased the quarterly cash dividend paid on our common stock to $0.13
per share. Our secured credit facility contains a restriction on our ability to pay cash dividends
on our common stock. At December 31, 2006, the aggregate amount of dividends we could pay was $633
million. The ranges of high and low sales prices for shares of our common stock for the periods
indicated were as follows:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Quarter Ended
|
|
|
|
March 31
|
|
June 30
|
|
September 30
|
|
December 31
|
|
|
|
2006
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
High
|
|
$
|
61.39
|
|
|
$
|
84.53
|
|
|
$
|
69.33
|
|
|
$
|
98.20
|
|
|
Low
|
|
$
|
36.05
|
|
|
$
|
57.00
|
|
|
$
|
55.82
|
|
|
$
|
60.30
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
March 31
|
|
June 30
|
|
September 30
|
|
December 31
|
|
|
|
2005
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
High
|
|
$
|
26.05
|
|
|
$
|
25.56
|
|
|
$
|
30.98
|
|
|
$
|
36.53
|
|
|
Low
|
|
$
|
18.03
|
|
|
$
|
19.52
|
|
|
$
|
22.00
|
|
|
$
|
26.60
|
|
|
|
Cumulative Total Stockholder Return
The graph set forth below shows the cumulative total stockholder return (i.e., price change plus
reinvestment of dividends) on our Common Stock from December 31, 2001 through December 31, 2006 as
compared to the S&P 500 Index, a Peer Group of companies, and the S&P Steel Index (formerly known
as the S&P Iron & Steel Index). We believe the Peer Group of companies, which is defined below, is
more representative of companies in our industry that serve similar markets, rather than the S&P
Steel Index, which primarily includes carbon steel manufacturers. Since the S&P Steel Index was
first used, the number of companies in this index has declined, and there are now only three
companies in this index (including ATI). Therefore, we do not believe this index is
representative, and we will cease using this index in future reports. The total stockholder return
for the Peer Group is weighted according to the respective issuers stock market capitalization at
the beginning of each period. The graph assumes that $100 was invested on December 31, 2001.
17
Comparison of Cumulative Five Year Total Return
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Base Period
|
|
|
|
|
|
|
|
|
|
|
|
Company / Index
|
|
Dec 01
|
|
Dec 02
|
|
Dec 03
|
|
Dec 04
|
|
Dec 05
|
|
Dec 06
|
|
Allegheny Technologies
|
|
|
100
|
|
|
|
39.30
|
|
|
|
87.18
|
|
|
|
144.96
|
|
|
|
243.75
|
|
|
|
616.46
|
|
|
S&P 500 Index
|
|
|
100
|
|
|
|
77.90
|
|
|
|
100.25
|
|
|
|
111.15
|
|
|
|
116.61
|
|
|
|
135.03
|
|
|
S&P 500 Steel Index
|
|
|
100
|
|
|
|
76.36
|
|
|
|
129.49
|
|
|
|
207.39
|
|
|
|
253.86
|
|
|
|
457.66
|
|
|
Peer Group
|
|
|
100
|
|
|
|
72.39
|
|
|
|
120.01
|
|
|
|
131.99
|
|
|
|
143.66
|
|
|
|
186.36
|
|
|
|
|
|
|
Peer Group companies for the cumulative five-year total return period ended December 31, 2006 were as follows:
|
|
AK Steel Holding Corp.
|
|
Quanex Corp.
|
|
ALCAN Inc.
|
|
Reliance Steel & Aluminum Co.
|
|
ALCOA Inc.
|
|
RTI International Metals Inc.
|
|
Carpenter Technology Corp.
|
|
Steel Dynamics Inc.
|
|
IPSCO Inc.
|
|
Titanium Metals Corp.
|
|
Kennametal Inc.
|
|
United States Steel Corp.
|
|
Nucor Corp.
|
|
|
Item 6. Selected Financial Data
The following table sets forth selected volume, price and financial information for ATI. The
financial information has been derived from our audited financial statements included elsewhere in
this report for the years ended December 31, 2006, 2005 and 2004. The historical selected financial
information may not be indicative of our future performance and should be read in conjunction with
the information contained in Item 7. Managements Discussion and Analysis of Financial Condition
and Results of Operations, and in Item 8. Financial Statements and Supplementary Data.
18
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
For the Years Ended December 31,
|
|
2006
|
|
|
2005
|
|
|
2004
|
|
|
2003
|
|
|
2002
|
|
|
|
|
Volume (000s lbs.):
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
High Performance Metals
nickel-based and specialty alloys
|
|
|
42,873
|
|
|
|
39,939
|
|
|
|
34,353
|
|
|
|
35,168
|
|
|
|
35,832
|
|
|
High Performance Metals titanium
mill products
|
|
|
27,361
|
|
|
|
24,882
|
|
|
|
22,012
|
|
|
|
18,436
|
|
|
|
19,044
|
|
|
High Performance Metals exotic alloys
|
|
|
4,304
|
|
|
|
4,018
|
|
|
|
4,318
|
|
|
|
4,245
|
|
|
|
3,712
|
|
|
Flat-Rolled Products:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
High value
|
|
|
502,524
|
|
|
|
495,868
|
|
|
|
508,946
|
|
|
|
470,500
|
|
|
|
360,349
|
|
|
Commodity
|
|
|
889,105
|
|
|
|
652,870
|
|
|
|
666,560
|
|
|
|
486,206
|
|
|
|
614,321
|
|
|
|
|
|
|
Flat-Rolled Products total
|
|
|
1,391,629
|
|
|
|
1,148,738
|
|
|
|
1,175,506
|
|
|
|
956,706
|
|
|
|
974,670
|
|
|
Average Prices (per lb.):
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
High Performance Metals
nickel-based and specialty alloys
|
|
$
|
14.35
|
|
|
$
|
11.25
|
|
|
$
|
8.60
|
|
|
$
|
6.57
|
|
|
$
|
6.39
|
|
|
High Performance Metals titanium
mill products
|
|
|
33.83
|
|
|
|
22.75
|
|
|
|
12.34
|
|
|
|
11.50
|
|
|
|
11.83
|
|
|
High Performance Metals exotic alloys
|
|
|
40.39
|
|
|
|
40.38
|
|
|
|
40.95
|
|
|
|
37.64
|
|
|
|
36.29
|
|
|
Flat-Rolled Products:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
High value
|
|
|
2.50
|
|
|
|
2.15
|
|
|
|
1.67
|
|
|
|
1.36
|
|
|
|
1.57
|
|
|
Commodity
|
|
|
1.61
|
|
|
|
1.26
|
|
|
|
1.18
|
|
|
|
0.83
|
|
|
|
0.78
|
|
|
Flat-Rolled Products combined average
|
|
|
1.93
|
|
|
|
1.64
|
|
|
|
1.39
|
|
|
|
1.09
|
|
|
|
1.07
|
|
|
|
|
(In millions)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
For the Years Ended December 31,
|
|
2006
|
|
|
2005
|
|
|
2004
|
|
|
2003
|
|
|
2002
|
|
|
|
|
Sales:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
High Performance Metals
|
|
$
|
1,806.6
|
|
|
$
|
1,246.0
|
|
|
$
|
794.1
|
|
|
$
|
641.7
|
|
|
$
|
630.0
|
|
|
Flat-Rolled Products
|
|
|
2,697.3
|
|
|
|
1,900.5
|
|
|
|
1,643.9
|
|
|
|
1,043.5
|
|
|
|
1,040.3
|
|
|
Engineered Products
|
|
|
432.7
|
|
|
|
393.4
|
|
|
|
295.0
|
|
|
|
252.2
|
|
|
|
237.5
|
|
|
|
|
Total sales
|
|
$
|
4,936.6
|
|
|
$
|
3,539.9
|
|
|
$
|
2,733.0
|
|
|
$
|
1,937.4
|
|
|
$
|
1,907.8
|
|
|
|
|
Operating profit (loss):
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
High Performance Metals
|
|
$
|
657.5
|
|
|
$
|
335.3
|
|
|
$
|
84.8
|
|
|
$
|
26.2
|
|
|
$
|
31.2
|
|
|
Flat-Rolled Products
|
|
|
344.3
|
|
|
|
149.9
|
|
|
|
61.5
|
|
|
|
(14.1
|
)
|
|
|
(8.6
|
)
|
|
Engineered Products
|
|
|
56.7
|
|
|
|
47.5
|
|
|
|
20.8
|
|
|
|
7.8
|
|
|
|
4.7
|
|
|
|
|
Total operating profit
|
|
$
|
1,058.5
|
|
|
$
|
532.7
|
|
|
$
|
167.1
|
|
|
$
|
19.9
|
|
|
$
|
27.3
|
|
|
|
|
Income (loss) before income taxes and cumulative
effect of change in accounting principle
|
|
$
|
869.2
|
|
|
$
|
307.1
|
|
|
$
|
19.8
|
|
|
$
|
(280.2
|
)
|
|
$
|
(103.8
|
)
|
|
Income (loss) before cumulative effect of change
in accounting principle
|
|
|
571.9
|
|
|
|
361.8
|
|
|
|
19.8
|
|
|
|
(313.3
|
)
|
|
|
(65.8
|
)
|
|
Cumulative effect of change in accounting
principle, net of tax
|
|
|
|
|
|
|
(2.0
|
)
|
|
|
|
|
|
|
(1.3
|
)
|
|
|
|
|
|
|
|
Net income (loss)
|
|
$
|
571.9
|
|
|
$
|
359.8
|
|
|
$
|
19.8
|
|
|
$
|
(314.6
|
)
|
|
$
|
(65.8
|
)
|
|
|
|
Basic net income (loss) per common share:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Income (loss) before cumulative effect of change
in accounting principle
|
|
$
|
5.74
|
|
|
$
|
3.76
|
|
|
$
|
0.23
|
|
|
$
|
(3.87
|
)
|
|
$
|
(0.82
|
)
|
|
Cumulative effect of change in accounting principle
|
|
|
|
|
|
|
(0.02
|
)
|
|
|
|
|
|
|
(0.02
|
)
|
|
|
|
|
|
|
|
Basic net income (loss) per common share
|
|
$
|
5.74
|
|
|
$
|
3.74
|
|
|
$
|
0.23
|
|
|
$
|
(3.89
|
)
|
|
$
|
(0.82
|
)
|
|
|
|
Diluted net income (loss) per common share:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Income (loss) before cumulative effect of change
in accounting principle
|
|
$
|
5.59
|
|
|
$
|
3.59
|
|
|
$
|
0.22
|
|
|
$
|
(3.87
|
)
|
|
$
|
(0.82
|
)
|
|
Cumulative effect of change in accounting principle
|
|
|
|
|
|
|
(0.02
|
)
|
|
|
|
|
|
|
(0.02
|
)
|
|
|
|
|
|
|
|
Diluted net income (loss) per common share
|
|
$
|
5.59
|
|
|
$
|
3.57
|
|
|
$
|
0.22
|
|
|
$
|
(3.89
|
)
|
|
$
|
(0.82
|
)
|
|
|
19
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(In millions except per share amounts and ratios)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
As of and for the Years Ended December 31,
|
|
2006
|
|
|
2005
|
|
|
2004
|
|
|
2003
|
|
|
2002
|
|
|
|
|
Dividends declared per common share
|
|
$
|
0.43
|
|
|
$
|
0.28
|
|
|
$
|
0.24
|
|
|
$
|
0.24
|
|
|
$
|
0.66
|
|
|
|
|
Ratio of earnings to fixed charges
|
|
|
18.1x
|
|
|
|
6.4x
|
|
|
|
1.4x
|
|
|
|
|
|
|
|
|
|
|
|
|
Working capital
|
|
$
|
1,342.4
|
|
|
$
|
923.1
|
|
|
$
|
667.4
|
|
|
$
|
348.6
|
|
|
$
|
453.7
|
|
|
|
|
Total assets
|
|
|
3,282.2
|
|
|
|
2,731.6
|
|
|
|
2,315.7
|
|
|
|
1,903.2
|
|
|
|
2,106.1
|
|
|
|
|
Long-term debt
|
|
|
529.9
|
|
|
|
547.0
|
|
|
|
553.3
|
|
|
|
504.3
|
|
|
|
509.4
|
|
|
|
|
Total debt
|
|
|
553.6
|
|
|
|
560.4
|
|
|
|
582.7
|
|
|
|
532.1
|
|
|
|
519.1
|
|
|
|
|
Cash and cash equivalents
|
|
|
502.3
|
|
|
|
362.7
|
|
|
|
250.8
|
|
|
|
79.6
|
|
|
|
59.4
|
|
|
|
|
Stockholders equity
|
|
|
1,492.6
|
|
|
|
799.9
|
|
|
|
425.9
|
|
|
|
174.7
|
|
|
|
448.8
|
|
|
|
Net income for 2005 included a $20.9 million net special gain, which included the tax benefit
associated with the reversal of the Companys remaining valuation allowance for U.S. Federal net
deferred tax assets of $44.9 million, partially offset by asset impairments and charges related to
legal matters of $22.0 million, and a $2.0 million charge, reported as a cumulative effect
accounting change, net of tax, for conditional asset retirement obligations. Net income in 2004 was
favorably impacted by a curtailment gain, net of restructuring costs, of $40.4 million. We did not
recognize an income tax provision or benefit in 2004 primarily as a result of the uncertainty
regarding full utilization of the net deferred tax asset and available operating loss
carryforwards. Net income (loss) in 2003 was adversely affected by restructuring and litigation
charges of $84.9 million and a $138.5 million charge to record a valuation allowance for the
majority of the Companys net deferred tax assets, and restructuring charges of $42.8 million in
2002.
Stockholders equity for 2006 includes a $47 million net increase to adjust pension and other
postretirement liabilities in accordance with adopting Statement of Financial Accounting Standards No. 158,
Employers Accounting for Defined Benefit Pension and Other Postretirement Plans, and an $81
million increase for the tax benefit on stock-based compensation. Stockholders equity for 2005
includes a $36 million reduction to adjust the minimum pension liability, and a $25 million
increase for the tax benefit on stock-based compensation. Stockholders equity for 2004 includes
$229.7 million in net proceeds from a common stock offering, and a $2 million increase to adjust
the minimum pension liability. Stockholders equity for 2003 includes the effect of recognizing a
$138.5 million valuation allowance on net deferred tax assets and a $47 million increase to adjust
the minimum pension liability, net of related tax effects. Stockholders equity for 2002 includes
the effect of recognizing a minimum pension liability of $406 million, net of related tax effects.
For purposes of determining the ratio of earnings to fixed charges, earnings include pre-tax
income plus fixed charges (excluding capitalized interest). Fixed charges consist of interest on
all indebtedness (including capitalized interest) plus that portion of operating lease rentals
representative of the interest factor (deemed to be one-third of operating lease rentals). For the
years ended December 31, 2003 and 2002, fixed charges exceeded earnings by $280.7 million and
$100.7 million, respectively.
The Company adopted Financial Accounting Standards Board Interpretation No. 47, Accounting
for Conditional Asset Retirement Obligations (FIN 47), an interpretation of Statement of
Financial Accounting Standards No. 143, Asset Retirement Obligations (SFAS 143) in the 2005
fourth quarter. The cumulative effect of adoption of FIN 47 was $2.0 million net of related tax
effects, or $0.02 per share. The Company adopted SFAS 143 on January 1, 2003. The cumulative effect
of adoption of SFAS 143 was $1.3 million net of related tax effects, or $0.02 per share. The
effects on prior years financial information were not material.
20
Item 7. Managements Discussion and Analysis of Financial Condition and Results of Operations
Certain statements contained in this Managements Discussion and Analysis of Financial Condition
and Results of Operations are forward-looking statements. Actual results or performance could
differ materially from those encompassed within such forward-looking statements as a result of
various factors, including those described below.
Overview of 2006 Financial Performance
ATIs 2006 performance was a record year for sales, segment operating profit, and earnings per
share. Net income for the full year 2006 increased 59% to $571.9 million, or $5.59 per share,
compared to $359.8 million, or $3.57 per share, for 2005. For 2006, return on capital employed was
34.5%, and return on stockholders equity was 49.9%. Sales increased 39% to $4.94 billion for 2006
as higher base-selling prices, the effect of raw material surcharges, and higher shipments for most
of our major products resulted from improved business conditions in most of the major markets we
serve. Our continued growth is being driven by strong and increasing demand from the aerospace and
defense market and increasing demand from those markets that are vital to the building and
rebuilding of the global infrastructure. For 2006, 30% of our sales were to the aerospace and
defense market, 19% to the chemical process industry and oil and gas markets, 11% to the electrical
energy market, and 3% to the medical market. These major high-value
markets represented 63% of
ATIs 2006 sales.
In our High Performance Metals segment, year-over-year sales increased 45% to $1.81 billion
due primarily to continuing strong demand from the aerospace and defense, medical, and oil and gas
markets for our titanium alloys, nickel-based alloys and superalloys, and vacuum melted specialty
alloys, and continued strong demand for our exotic materials, especially from the aerospace and
defense, chemical process industry, and electrical energy markets. Operating profit for the High
Performance Metals segment improved to $657.5 million, a 96% increase compared to 2005, due
primarily to the improved pricing and increased shipments resulting from increased demand and
benefits from our gross cost reduction efforts, partially offset by the impact on the LIFO
inventory accounting methodology from rising raw material costs.
In our Flat-Rolled Products segment, sales increased 42% to $2.70 billion due primarily to
strong demand for our products from the global chemical process industry, electrical energy, and
oil and gas markets, and good demand from construction, appliance and automotive markets. This
improvement in demand, combined with higher base prices for most of the Flat-Rolled Products
segment products and the benefits from our gross cost reduction efforts, more than offset the
significant negative impact of the LIFO inventory accounting methodology from rising raw material
costs, and resulted in an operating profit for this segment of $344.3 million, a 130% improvement
compared to 2005.
Results for our Engineered Products segment also improved, as sales increased to $432.7
million, or 10%, compared to 2005, and operating profit increased to $56.7 million, a 19% increase,
due to improved demand from the oil and gas, construction and mining, aerospace and defense, power
generation, and transportation markets, plus benefits from our gross cost reduction actions.
Total segment operating profit increased to $1.06 billion, an increase of $525.8 million
compared to 2005. This significant improvement in segment profitability was achieved after LIFO
inventory valuation reserve charges of $197.0 million, due primarily to higher overall raw material
costs, which was partially offset by the benefits of $141 million in gross cost reductions across
the Company.
During 2006, we continued to enhance our leading market positions, reduce costs, and improve
our balance sheet. We also realized continued success in implementing the ATI Business System,
which is driving lean manufacturing throughout our operations. Our accomplishments during 2006 from
these important efforts included:
|
|
|
We continued to grow our global market presence as direct
international sales reached a record $1.17 billion, or 24% of total
sales, an increase of $300.7 million compared to 2005. During 2006,
we realigned our European sales and distribution organization to
better support our customer needs and the distribution of ATIs
products.
|
|
|
|
|
|
We continued to build a foundation for further profitable growth.
During 2006, we entered into long-term agreements with aerospace and
defense customers to supply them with titanium and nickel-based
superalloys.
|
21
|
|
|
The commercial aerospace markets use of titanium is expected to increase significantly as new
aircraft airframe production is utilizing a larger percentage of titanium material. For
example, the new Boeing 787 Dreamliner airframe (excluding engines), which is expected to be put
into service beginning in 2008, will utilize approximately 250,000 pounds (buy weight) of titanium
alloys per aircraft, a significant increase over any previous commercial aircraft airframe. The
new aircraft designs from Airbus, the A380 and A350-XWB, and from defense contractors are also
expected to utilize a greater percentage of titanium. Given the significant backlog and
development plans by the aircraft manufacturers, this increasing demand for titanium alloys is
expected to last into the next decade.
|
|
|
|
|
|
We significantly increased self-funded strategic capital investments in our businesses to
support the growth in our markets, especially for titanium and titanium alloys, nickel-based
alloys and superalloys, and vacuum melted specialty alloys. The major strategic capital
projects include:
|
|
|
|
|
A significant upgrade to and restarting of our titanium sponge facility in Albany, OR at
a total capital investment of approximately $100 million, including the announced expansion
in February 2007. Titanium sponge is an important raw material used to produce our titanium
mill products. The annual production of titanium sponge from our Albany, OR facility will
ramp up through the first half of 2007 when it will reach an annualized production rate of
approximately 16 million pounds, and will reach approximately 20 million pounds of
annualized production by the second half of 2008 when all phases are completed.
|
|
|
|
|
|
|
The design and construction of a greenfield premium-grade titanium sponge facility in
Rowley, UT, which will be the first greenfield titanium sponge facility built in the U.S. in
over thirty years. The updated estimate of the cost of this facility is expected to be $425 to $450 million,
including engineering and design for future expansion. Titanium sponge production
from the Rowley UT facility is expected to begin in late 2008 and
reach an initial annualized
production rate of approximately 24 million pounds in 2009. When the Oregon and Utah
facilities are operational in 2009, our total annual titanium sponge production
capacity is expected to be approximately 44 million pounds, and is intended to supplement
our purchased titanium sponge and purchased titanium scrap requirements.
|
|
|
|
|
|
|
The design and construction of a $215 million titanium alloys and nickel-based alloys and
superalloy forging facility in the Carolinas. This new facility, which is expected to be
constructed in phases through 2009, will include a new 10,000 ton
press forge and a new 700mm
rotary forge, both of which will be the largest of their kind in the world for producing
these types of alloys. It will also include billet conditioning and finishing equipment. We
will also add our fourth Plasma Arc Melt (PAM) furnace for cold hearth melting premium
titanium alloys, primarily for aeroengine rotating-quality
applications, and we will build
additional vacuum arc remelt (VAR) capacity to support premium nickel-based superalloy and
titanium growth. These investments are expected to commence production in phases through
2009.
|
|
|
|
|
|
|
A $60 million upgrade and expansion of our titanium and titanium alloys, nickel-based
alloys, stainless steel, and specialty alloys plate finishing facility in Washington, PA.
This upgrade and expansion is expected to be completed in 2008.
|
|
|
|
|
|
|
A significant expansion of our capability to produce ammonium paratungstate (APT), a
raw material used in the production of tungsten powder and tungsten materials in our
Engineered Products segment. This investment is expected to position ATI to be
self-sufficient for APT, by producing this important raw material from scrap at a much lower
cost than purchased APT. The full benefit of this expansion is expected to be realized
beginning in the first half of 2007.
|
|
|
|
|
|
|
Our Chinese joint venture company known as Shanghai STAL Precision Stainless Steel
Company Limited (STAL), in which ATI has a 60% interest, commenced an expansion of its
Precision Rolled Strip operations in Shanghai, China. This expansion is expected to more
than triple STALs precision rolling and slitting capacity when fully operational in 2009.
|
|
|
|
We realized strong cash generation in 2006. Cash on hand at the end of 2006 was $502.3
million, an increase of $140 million compared to the end of 2005. This increase in cash is
after investing $534 million in managed working capital due primarily to higher business
activity, $235 million in capital expenditures, $100 million in a
|
22
|
|
|
voluntary cash contribution to our U.S. qualified defined benefit pension plan, and $43 million
in dividend payments.
|
|
|
|
|
|
We continued to strengthen our balance sheet. Our net debt to total
capitalization improved to 3.3% at December 31, 2006, compared to
19.8%, 43.8% and 72.1% at year-end 2005, 2004 and 2003, respectively.
At the end of 2006, our U.S. qualified defined benefit pension plan
was essentially fully funded. This is significant as the previous
funded status of the plan had a significant negative impact on our
balance sheet. As a result of the improvement in funding status,
total retirement benefit expense is expected to decline by $50 million
in 2007, compared to 2006.
|
|
|
|
|
|
We continued to realize significant improvement in safety across ATIs
operations. As a result of our continuing focus on and commitment to
safety, in 2006 our OSHA Total Recordable Incident Rate improved by
19% and our Lost Time Case Rate improved by 42%, both compared to
2005.
|
|
|
|
|
|
We realized continued success from the ATI Business System, which is
driving lean manufacturing throughout our operations. In addition to
$141 million in gross cost reductions achieved in 2006, which was $41
million higher than our 2006 goal of $100 million, and the improved
safety performance discussed above, another result of our ATI Business
System efforts was the continuing improvement in managed working
capital. We define managed working capital as accounts receivable and
gross inventories less accounts payable. At December 31, 2006,
managed working capital improved to 29.0% of annualized sales compared
to 30.3% at 2005 year-end.
|
|
|
|
|
|
With the continuing strength in our major end markets and confidence
in ATIs ability to continue to generate strong cash flow over the
next several years, the Board of Directors increased the quarterly
dividend by 30% to $0.13 per share in December 2006. This is the
second consecutive year the Board has significantly increased the
dividend.
|
As a result of these accomplishments, we believe that the foundation has been set for further
profitable growth in 2007 and beyond. Our businesses are positioned to continue to deliver
outstanding operational performance. We have several major long-term customer supply agreements in
place, and ATIs presence and sales are growing around the world. Our strategic capital projects
are expected to contribute significant growth with very good returns beginning in 2007. To achieve
additional growth and to meet the demands for our products from the global markets we serve, we
plan $450 to $500 million of self-funded capital investments in 2007, approximately 70% of which is
related to the previously announced strategic growth projects discussed above. We expect strong
cash flow in 2007 to support this level of investment. We remain dedicated to our disciplined plan
and vision of
Building the Worlds Best Specialty Metals Company
.
Results of Operations
Sales were $4.94 billion in 2006, $3.54 billion in 2005 and $2.73 billion in 2004. Direct
international sales represented approximately 24% of 2006 sales, 25% of 2005 sales and 20% of 2004
sales.
Segment operating profit was $1.06 billion in 2006, $532.7 million in 2005, and $167.1 million
in 2004. Our measure of segment operating profit, which we use to analyze the performance and
results of our business segments, excludes income taxes, corporate expenses, net interest expense,
retirement benefit expense, other costs net of gains on asset sales, curtailment gains and
restructuring costs, if any. We believe segment operating profit, as defined, provides an
appropriate measure of controllable operating results at the business segment level.
Income before tax and the cumulative effect of change in accounting principle was $869.2
million in 2006, $307.1 million in 2005, and $19.8 million in 2004. For 2005, income before tax
included a restructuring charge of $23.9 million for asset impairments and a charge of $12.6
million for legal matters. Income before tax for 2004 included a curtailment gain, net of
restructuring charges, of $40.4 million.
Income before the cumulative effect of change in accounting principle was $571.9 million for
2006, $361.8 million for 2005, and $19.8 million for 2004. Net income for 2005 included a $20.9
million net special gain, which included a tax benefit associated with the reversal of the
Companys remaining valuation allowance for U.S. Federal net deferred tax assets, partially offset
by asset impairments charges in the Flat-Rolled Products segment, charges
23
for legal matters, and the cumulative effect of adopting a new accounting principle for
conditional asset retirement obligations. Results for 2004 did not include an income tax provision
or benefit for current or deferred taxes primarily as a result of the uncertainty regarding full
utilization of our net deferred tax assets and available operating loss carryforwards. Net income
for 2004 included a curtailment gain, net of restructuring costs of $40.4 million, related to the
elimination of retiree medical benefits for certain non-collectively bargained employees beginning
in 2010, and costs associated with the acquisition of the J&L assets and the 2004 labor agreement.
We operate in three business segments: High Performance Metals, Flat-Rolled Products and
Engineered Products. These segments represented the following percentages of our total revenues and
segment operating profit for the years indicated:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
2006
|
|
2005
|
|
2004
|
|
|
|
|
|
|
|
Operating
|
|
|
|
|
|
Operating
|
|
|
|
|
|
Operating
|
|
|
|
Revenue
|
|
Profit
|
|
Revenue
|
|
Profit
|
|
Revenue
|
|
Profit
|
|
High Performance Metals
|
|
|
37
|
%
|
|
|
62
|
%
|
|
|
35
|
%
|
|
|
63
|
%
|
|
|
29
|
%
|
|
|
51
|
%
|
|
|
|
|
|
Flat-Rolled Products
|
|
|
54
|
%
|
|
|
33
|
%
|
|
|
54
|
%
|
|
|
28
|
%
|
|
|
60
|
%
|
|
|
37
|
%
|
|
|
|
|
|
Engineered Products
|
|
|
9
|
%
|
|
|
5
|
%
|
|
|
11
|
%
|
|
|
9
|
%
|
|
|
11
|
%
|
|
|
12
|
%
|
|
|
|
|
Information with respect to our business segments is presented below and in Note 10 of the
Notes to Consolidated Financial Statements.
High Performance Metals
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(In millions)
|
|
2006
|
|
% Change
|
|
2005
|
|
% Change
|
|
2004
|
|
|
|
Sales to external customers
|
|
$
|
1,806.6
|
|
|
|
45
|
%
|
|
$
|
1,246.0
|
|
|
|
57
|
%
|
|
$
|
794.1
|
|
|
|
|
Operating profit
|
|
|
657.5
|
|
|
|
96
|
%
|
|
|
335.3
|
|
|
|
295
|
%
|
|
|
84.8
|
|
|
|
|
Operating profit as a percentage of sales
|
|
|
36.4
|
%
|
|
|
|
|
|
|
26.9
|
%
|
|
|
|
|
|
|
10.7
|
%
|
|
|
|
Direct international sales as a percentage of sales
|
|
|
31.5
|
%
|
|
|
|
|
|
|
32.6
|
%
|
|
|
|
|
|
|
32.5
|
%
|
|
|
Our High Performance Metals segment produces, converts and distributes a wide range of high
performance alloys, including titanium and titanium-based alloys, nickel- and cobalt-based alloys
and superalloys, exotic alloys such as zirconium, hafnium, niobium, nickel-titanium, and their
related alloys, and other specialty metals, primarily in long product forms such as ingot, billet,
bar, rod, wire, shapes and rectangles, and seamless tube. These products are designed for the high
performance requirements of such major end markets as aerospace and defense,
chemical process industry, oil and gas, medical and electrical energy. The operating units in this segment are ATI Allvac,
ATI Allvac Ltd (U.K.) and ATI Wah Chang.
2006 Compared to 2005
Sales for the High Performance Metals segment for 2006 were $1.81 billion, or 45% higher than 2005,
due primarily to increased volume and higher average selling prices for most of our products driven
by strong demand from the aerospace and defense, medical, oil and gas, chemical process industry,
and electrical energy markets. Comparative information on the segments products for the years
ended December 31, 2006 and 2005 was:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
For the Years Ended December 31,
|
|
2006
|
|
2005
|
|
% Change
|
|
|
|
|
|
|
|
Volume (000s lbs.):
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Nickel-based and specialty steel alloys
|
|
|
42,873
|
|
|
|
39,939
|
|
|
|
7
|
%
|
|
|
|
|
|
Titanium mill products
|
|
|
27,361
|
|
|
|
24,882
|
|
|
|
10
|
%
|
|
|
|
|
|
Exotic alloys
|
|
|
4,304
|
|
|
|
4,018
|
|
|
|
7
|
%
|
|
|
|
|
|
|
|
Average Prices (per lb.):
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Nickel-based and specialty steel alloys
|
|
$
|
14.35
|
|
|
$
|
11.25
|
|
|
|
28
|
%
|
|
|
|
|
|
Titanium mill products
|
|
$
|
33.83
|
|
|
$
|
22.75
|
|
|
|
49
|
%
|
|
|
|
|
|
Exotic alloys
|
|
$
|
40.39
|
|
|
$
|
40.38
|
|
|
|
|
%
|
|
|
|
|
|
|
Aerospace represents a significant market for our High Performance Metals segment, especially
for premium quality specialty metals used in the manufacture of jet engines for the original
equipment and spare parts markets. In addition, we are becoming a larger supplier of specialty
metals used in airframe construction. In January 2007, we
24
announced a long-term sourcing agreement with GE Aviation for the supply of premium titanium,
nickel-based superalloy, and vacuum-melted specialty alloy products for commercial and military jet
engine applications. Total revenues under this agreement plus Allvacs direct sales to GE
Aviation for the period 2007 through 2011 may exceed $2 billion. In addition, in October 2006 we
announced a long-term agreement with The Boeing Company to supply titanium products for the Boeing
787 Dreamliner and other Boeing aircraft airframes. Total revenues under this contract are valued
at approximately $2.5 billion for the years 2007 through 2015. This long-term agreement includes
both long-product forms which are manufactured within the High Performance Metals segment, and a
significant amount of plate products which are manufactured utilizing assets of both the High
Performance Metals and Flat-Rolled Products segments. Revenues and profits associated with these
mill products covered by the long-term agreement are included primarily in the results for the High
Performance Metals segment. The demand from the aerospace market has recovered from the decline
after the effect of the tragedy of September 11, 2001. Annually, revenue passenger miles and
freight miles have increased 9.7% and 7.3%, respectively, since 2003, according to the
International Civil Aviation Organization (ICAO). The ICAO expects this growth trend to continue at
over 6% annually well into the next decade based on the demand for passenger and freight travel
from developing economies, especially in Asia and the Middle East, and continuing economic growth
in the rest of the world. Commercial and military jet aircraft deliveries of new aircraft have
increased 8.4% annually since 2003. Independent forecasts from both Airline Monitor and Forecast
International project continuing growth of commercial and military jet aircraft deliveries into the
next decade. Due to manufacturing cycle times, demand for our specialty metals leads the
deliveries of new aircraft by 12 to 18 months. In addition, as our specialty metals are used in jet
engines, demand for our products for spare parts is impacted by aircraft flight activity and engine
refurbishment requirements of U.S. and foreign aviation regulatory authorities.
Airline Miles Revenue Passenger
(Worldwide, per year)
Airline Miles Revenue Passenger
(Worldwide, per year)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
70
|
|
75
|
|
80
|
|
85
|
|
90
|
|
95
|
|
00
|
|
05
|
|
06
|
|
Revenue Passenger Miles
(Billions)
|
|
|
286
|
|
|
|
433
|
|
|
|
677
|
|
|
|
850
|
|
|
|
1177
|
|
|
|
1397
|
|
|
|
1875
|
|
|
|
2310
|
|
|
|
2455
|
|
Source: International Civil Aviation Organization
25
Airline Miles Freight
(Worldwide, per year)
Airline Miles Freight
(Worldwide, per year)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
70
|
|
75
|
|
80
|
|
85
|
|
90
|
|
95
|
|
00
|
|
05
|
|
06
|
|
Freight Ton-Miles
(Billions)
|
|
|
16
|
|
|
|
15
|
|
|
|
23
|
|
|
|
30
|
|
|
|
44
|
|
|
|
61
|
|
|
|
85
|
|
|
|
98
|
|
|
|
105
|
|
Source: International Civil Aviation Organization
26
Commercial & Military Jet Aircraft Build Rate and Forecast
(Worldwide, per year)
Source: Airline Monitor, Forecast International
Commercial & Military Jet Aircraft Build Rate and Forecast
(Worldwide, per year)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
1996
|
|
1997
|
|
1998
|
|
1999
|
|
2000
|
|
2001
|
|
2002
|
|
2003
|
|
2004
|
|
2005
|
|
2006
|
|
2007
|
|
2008
|
|
2009
|
|
2010
|
|
Boeing deliveries
|
|
|
271
|
|
|
|
374
|
|
|
|
563
|
|
|
|
620
|
|
|
|
491
|
|
|
|
527
|
|
|
|
381
|
|
|
|
281
|
|
|
|
285
|
|
|
|
290
|
|
|
|
398
|
|
|
|
445
|
|
|
|
518
|
|
|
|
561
|
|
|
|
620
|
|
|
Airbus deliveries
|
|
|
126
|
|
|
|
182
|
|
|
|
229
|
|
|
|
294
|
|
|
|
311
|
|
|
|
325
|
|
|
|
303
|
|
|
|
305
|
|
|
|
320
|
|
|
|
378
|
|
|
|
434
|
|
|
|
492
|
|
|
|
519
|
|
|
|
525
|
|
|
|
585
|
|
|
Regional jet del.
|
|
|
54
|
|
|
|
92
|
|
|
|
137
|
|
|
|
193
|
|
|
|
293
|
|
|
|
325
|
|
|
|
300
|
|
|
|
308
|
|
|
|
309
|
|
|
|
260
|
|
|
|
169
|
|
|
|
175
|
|
|
|
163
|
|
|
|
164
|
|
|
|
145
|
|
|
Military A/C del.
|
|
|
129
|
|
|
|
193
|
|
|
|
205
|
|
|
|
175
|
|
|
|
130
|
|
|
|
113
|
|
|
|
128
|
|
|
|
160
|
|
|
|
243
|
|
|
|
243
|
|
|
|
268
|
|
|
|
253
|
|
|
|
232
|
|
|
|
253
|
|
|
|
249
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total deliveries
|
|
|
580
|
|
|
|
841
|
|
|
|
1,134
|
|
|
|
1,282
|
|
|
|
1,225
|
|
|
|
1,290
|
|
|
|
1,112
|
|
|
|
1,054
|
|
|
|
1,157
|
|
|
|
1,171
|
|
|
|
1,269
|
|
|
|
1,365
|
|
|
|
1,432
|
|
|
|
1,503
|
|
|
|
1,599
|
|
High Performance Metals segment operating profit for 2006 increased due to higher volume
and pricing, and also improved due to product mix. Segment results in 2006 and 2005 were adversely
affected by higher raw material costs, which increased significantly in the past several years.
These higher costs, while largely recovered in product selling prices through raw material indices,
had a negative effect on cost of sales as a result of our LIFO inventory accounting methodology,
resulting in LIFO inventory valuation reserve charges of $49.4 million in 2006 and $46.0 million in
2005.
We continued to aggressively reduce costs in 2006. Gross cost reductions, before the effects
of inflation, totaled approximately $39 million. Major areas of gross cost reductions included $20
million from procurement, $15 million from operating efficiencies, and $3 million from salaried and
hourly labor cost savings.
To support our strategic growth initiatives in the High Performance Metals segment, in 2006 we
committed to significantly expand our manufacturing capabilities. Including projects announced in
2005, 2006 and to date in 2007, we will spend approximately $625 million in a multi-phase titanium products expansion that is
expected to yield 44 million pounds of annual titanium sponge production capacity and increase
ATIs annual titanium melt capacity by at least 25 million pounds. These strategic titanium
capital investments are designed to expand and enhance ATIs capacity
27
and capabilities to meet current and expected demand growth from the aerospace (both engine
and airframe), defense, chemical process industry, oil and gas, and medical markets. The expansion
includes the following phases:
|
§
|
|
The Phase I expansion of ATIs titanium production capabilities was announced on
July 15, 2005, and includes upgrading and restarting ATIs titanium sponge facility in Albany,
OR, constructing a third Plasma Arc Melt (PAM) cold-hearth furnace in Bakers, NC, adding three
vacuum arc remelt (VAR) furnaces, expanding high-value plate products capacity by 25%, and
continued upgrading of ATIs cold-rolling assets used in producing titanium sheet and strip
products. Phase I of our Albany, OR titanium sponge facility is now fully operational with
six new furnaces producing at an annualized rate of approximately 8.0 million pounds, and the
additional VAR melt capacity began operations in late 2006 and early 2007. The new PAM
furnace is expected to begin operations in the first quarter 2007. Plasma arc melting is a
superior cold-hearth melting process for making alloyed titanium products for jet engine
rotating parts, medical applications, and other critical applications. VAR melting is a
consumable electrode re-melting process that improves the cleanliness and chemical homogeneity
of the alloys.
|
|
|
|
§
|
|
The Phase II expansion of ATIs titanium production capabilities was announced
on March 17, 2006, and includes additional titanium sponge capacity at ATIs facility in
Albany, OR, and an additional VAR furnace at ATIs facility in Bakers, NC. We expect the
additional titanium sponge production capacity of approximately 4.0 million pounds annually
from this phase to begin operation in the first half of 2007. The additional VAR melt
capacity is expected to begin operation early in the third quarter 2007.
|
|
|
|
§
|
|
The Phase III expansion of ATIs titanium production capabilities was announced
on June 22, 2006, and includes additional titanium sponge capacity and an additional VAR
furnace at ATIs facility in Albany, OR. The additional titanium sponge production capacity
of approximately 4.0 million pounds annually from this phase is expected to be fully
operational in the second half of 2007. As a result of Phases I, II and III, we expect our
annual titanium sponge production capacity from the Albany facility to be approximately 12
million pounds in 2007, expanding to approximately 16 million pounds in 2008. The additional
VAR melt capacity is expected to begin operations in two stages, with the first start-up in
the second quarter of 2007 and the second stage in the first quarter of 2008.
|
|
|
|
§
|
|
In June 2006, we announced the Phase IV expansion to our titanium capabilities.
Phase IV is a greenfield premium-grade titanium sponge facility to be built in Rowley, UT
with an annual capacity of 24 million pounds. This investment, which is estimated at $425 to $450
million including engineering and design for future expansion, is aimed at increasing our
capacity to produce titanium alloys for aerospace and defense applications. Premium-grade
sponge is essential for many aerospace applications, including rotating quality titanium
alloys used for new jet engines and spare parts. We expect initial production of titanium
sponge to begin in the third quarter 2008 and grow to an initial annualized rate of 24 million pounds
in 2009.
|
|
|
|
§
|
|
In February 2007, we announced a further expansion of our Albany, OR titanium
sponge production capabilities. The additional expansion of the Albany, OR facility will
include four sponge furnaces and related processing operations, and is expected to be in
service in the first half of 2008. This expansion is expected to add another 4 million pounds
of titanium sponge capacity annually.
|
Upon
the completion of these phases, ATIs internal titanium sponge annual capacity of
approximately 44 million pounds will be in addition to the amount of titanium sponge and titanium
scrap ATI purchases from external sources.
Additionally, in January 2007, we announced the expansion of our titanium and nickel-based
superalloy capabilities at facilities located in Bakers, NC. The purpose of the capital project is
to meet growing demand from the aerospace and defense (both jet engine and airframe), electrical
energy, medical, chemical process industry, and oil and gas markets. The total investment is
approximately $215 million, which is expected to be nearly evenly spread over the next three years.
ATI expects this self-funded project to be substantially completed by the end of 2009. The
project will include:
|
§
|
|
Additional forging capacity. ATI plans to add an integrated 10,000 ton press
forge, 700mm rotary forge, conditioning, finishing, and inspection facility to support
increased forged product requirements. The new
|
28
|
|
|
forging capacity is expected to be operational by the third quarter 2009. Forging is a
hot-forming process that produces wrought forging billet and forged machining bar from an ingot.
|
|
|
|
§
|
|
A fourth PAM furnace to support premium titanium alloy growth requirements. ATI
expects this fourth PAM furnace to begin production by the fourth quarter 2008.
|
|
|
|
§
|
|
Additional VAR capacity to support premium nickel-based superalloy and titanium
growth. ATI expects one new VAR to be in production in the first quarter 2008. The remaining
four VAR furnaces would be installed as needed.
|
2005 Compared to 2004
Sales for the High Performance Metals segment increased 57% to $1.25 billion in 2005 primarily due
to continuing strong demand from the aerospace, defense, oil and gas, medical, and power generation
markets. Our exotic alloys business continued to benefit from demand from the aerospace, defense,
chemical processing, and medical markets. Operating profit for the High Performance Metals segment
improved significantly to $335.3 million as a result of increased shipments for most of our
products, higher selling prices, and the benefits of gross cost reductions. Comparative information
on the segments products for the years ended December 31, 2005 and 2004 was:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
For the Years Ended December 31,
|
|
2005
|
|
2004
|
|
% Change
|
|
|
|
Volume (000s lbs.):
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Nickel-based and specialty steel alloys
|
|
|
39,939
|
|
|
|
34,353
|
|
|
|
16
|
%
|
|
Titanium mill products
|
|
|
24,882
|
|
|
|
22,012
|
|
|
|
13
|
%
|
|
Exotic alloys
|
|
|
4,018
|
|
|
|
4,318
|
|
|
|
(7
|
%)
|
|
|
|
Average Prices (per lb.):
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Nickel-based and specialty steel alloys
|
|
$
|
11.25
|
|
|
$
|
8.60
|
|
|
|
31
|
%
|
|
Titanium mill products
|
|
$
|
22.75
|
|
|
$
|
12.34
|
|
|
|
84
|
%
|
|
Exotic alloys
|
|
$
|
40.38
|
|
|
$
|
40.95
|
|
|
|
(1
|
%)
|
|
|
Segment operating profit for 2005 and 2004 was adversely affected by higher raw material
costs, which increased significantly in the past several years. These higher costs, while largely
recovered in product selling prices through raw material indices, had a negative effect on cost of
sales as a result of our LIFO inventory accounting methodology, resulting in LIFO inventory
valuation reserve charges of $46.0 million in 2005, and $16.2 million in 2004.
We continued to aggressively reduce costs in 2005. Gross cost reductions, before the effects
of inflation, for 2005 totaled approximately $34 million. Major areas of gross cost reductions
included $20 million from operating efficiencies, $11 million from procurement, and $2 million from
salaried and hourly labor cost savings.
In 2005, we announced strategic capital investments to expand our titanium and nickel-based
alloy and specialty alloy production capabilities, which included approximately $110 million for:
|
|
|
Upgrading and restarting approximately one-half of the capacity of our idled titanium sponge facility in Albany, Oregon.
|
|
|
|
|
|
Constructing a third plasma arc melt cold-hearth furnace at ATI Allvacs North Carolina operations.
|
|
|
|
|
|
Upgrading and expanding vacuum induction melt (VIM) capacity. VIM is a melting process designed for premium grades of
nickel-based alloys and superalloys that require more precise chemistry control and lower impurity levels.
|
|
|
|
|
|
Installation of new electro-slag re-melt (ESR) and new VAR furnaces. ESR and VAR furnaces are consumable electrode
re-melting processes used to improve both the cleanliness and metallurgical structure of alloys.
|
29
Flat-Rolled Products
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(In millions)
|
|
2006
|
|
% Change
|
|
2005
|
|
% Change
|
|
2004
|
|
|
|
Sales to external customers
|
|
$
|
2,697.3
|
|
|
|
42
|
%
|
|
$
|
1,900.5
|
|
|
|
16
|
%
|
|
$
|
1,643.9
|
|
|
|
|
Operating income
|
|
|
344.3
|
|
|
|
130
|
%
|
|
|
149.9
|
|
|
|
144
|
%
|
|
|
61.5
|
|
|
|
|
Operating income as a percentage of sales
|
|
|
12.8
|
%
|
|
|
|
|
|
|
7.9
|
%
|
|
|
|
|
|
|
3.7
|
%
|
|
|
|
Direct international sales as a
percentage of sales
|
|
|
18.0
|
%
|
|
|
|
|
|
|
18.5
|
%
|
|
|
|
|
|
|
12.9
|
%
|
|
|
Our Flat-Rolled Products segment produces, converts and distributes stainless steel,
nickel-based alloys, and titanium and titanium-based alloys, in a variety of product forms
including plate, sheet, engineered strip, and Precision Rolled Strip
®
products,
as well as grain-oriented silicon electrical steel sheet, and tool steels. The major end markets
for our flat-rolled products are construction and mining, automotive, electrical energy, food
processing equipment and appliances, machine and cutting tools,
chemical process industry, oil and gas,
electronics, communication equipment and computers. The operations in this segment are ATI
Allegheny Ludlum, our 60% interest in the Chinese joint venture company known as Shanghai STAL
Precision Stainless Steel Company Limited (STAL), and our 50% interest in the industrial titanium
joint venture known as Uniti LLC. The remaining 40% interest in STAL is owned by the Baosteel
Group, a state authorized investment company whose equity securities are publicly traded in the
Peoples Republic of China. The financial results of STAL are consolidated into the segments
operating results with the 40% interest of our minority partner recognized in the consolidated
statement of income as other income or expense. The remaining 50% interest in Uniti LLC is held by
VSMPO, a Russian producer of titanium, aluminum, and specialty steel products. We account for the
results of the Uniti joint venture using the equity method since we do not have a controlling
interest.
2006 Compared to 2005
Sales for the Flat-Rolled Products segment for 2006 were $2.70 billion, or 42% higher than 2005,
due primarily to increased volume, higher average base-selling prices and higher average raw
material surcharges. Comparative information on the segments products for the years ended December
31, 2006 and 2005 was:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
For the Years Ended December 31,
|
|
2006
|
|
2005
|
|
% Change
|
|
|
|
Volume (000s lbs.):
|
|
|
|
|
|
|
|
|
|
|
|
|
|
High value
|
|
|
502,524
|
|
|
|
495,868
|
|
|
|
1
|
%
|
|
Commodity
|
|
|
889,105
|
|
|
|
652,870
|
|
|
|
36
|
%
|
|
|
|
|
|
Total Flat-Rolled Products
|
|
|
1,391,629
|
|
|
|
1,148,738
|
|
|
|
21
|
%
|
|
|
|
Average Prices (per lb.):
|
|
|
|
|
|
|
|
|
|
|
|
|
|
High value
|
|
$
|
2.50
|
|
|
$
|
2.15
|
|
|
|
16
|
%
|
|
Commodity
|
|
$
|
1.61
|
|
|
$
|
1.26
|
|
|
|
28
|
%
|
|
Total Flat-Rolled Products
|
|
$
|
1.93
|
|
|
$
|
1.64
|
|
|
|
18
|
%
|
|
|
Shipments in 2006 increased by 21% to 1,392 million pounds compared to shipments of 1,149
million pounds for 2005. The average transaction prices to customers, which includes the effect of
higher average raw material surcharges and higher average base-selling prices, increased by 18% to
$1.93 per pound in 2006.
Our Flat-Rolled Products segment high-value product shipments, which include engineered strip,
Precision Rolled Strip, super stainless steel, nickel-based alloys, titanium and titanium-based
alloys, grain-oriented silicon electrical steel, and tool steel
products, increased 1%, with average
transaction prices for our high-value products increasing 16%, primarily due to product mix. Demand
was strong for our specialty stainless, grain-oriented silicon, titanium, and nickel-based alloy
products from the chemical process industry, oil and gas, electrical energy, and aerospace and
defense markets. Our direct international sales, which were primarily comprised of high value
products, increased $134.7 million to $485.6 million, and represented 18% of sales for the
Flat-Rolled Products segment.
Shipments of our commodity products, which primarily include stainless steel hot roll and cold
roll sheet, and stainless steel plate, increased 36% and average transaction prices for these
products increased 28%. In 2006, consumption in the U.S. of stainless steel strip, sheet and plate
products increased approximately 15%, compared to
30
2005 consumption, according to the Specialty Steel Institute of North America (SSINA). Demand
was strong for our commodity products from the biofuel (ethanol) and construction markets and was
good from the appliance and appliance related markets. Our The Switch is On marketing campaign had
its best year ever in 2006 as customers in both the U.S. and Europe recognized the value of lean
nickel products, such as AL201HP stainless, which has one-half the nickel content as the most
common Type 304 stainless product with similar corrosion properties and greater strength. In 2006,
shipments of 201HP increased over 40% compared to 2005. In addition, we now sell other commodity
stainless products in Europe, which demonstrates that we are a cost competitive global producer of
these products.
Apparent Domestic Consumption
Stainless Sheet and Strip
(Millions of tons)
|
|
|
|
|
*
|
|
2006 represents November YTD, annualized
|
Apparent Domestic Consumption
Stainless Sheet and Strip
(Millions of tons)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
00
|
|
01
|
|
02
|
|
03
|
|
04
|
|
05
|
|
06
|
|
Millions/Tons
|
|
|
1.90
|
|
|
|
1.55
|
|
|
|
1.59
|
|
|
|
1.59
|
|
|
|
1.81
|
|
|
|
1.62
|
|
|
|
1.87
|
|
Source: SSINA
The majority of our flat-rolled products are sold at prices that include surcharges for raw
materials, including purchased scrap, that are required to manufacture our products. These raw
materials include iron, nickel, chromium, and molybdenum.
31
Iron Scrap Prices
($/Gross Ton)
Iron Scrap Prices
($/Gross Ton)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
97
|
|
98
|
|
99
|
|
00
|
|
01
|
|
02
|
|
03
|
|
04
|
|
05
|
|
06
|
|
|
|
|
144
|
|
|
|
83
|
|
|
|
129
|
|
|
|
85
|
|
|
|
74
|
|
|
|
105
|
|
|
|
173
|
|
|
|
233
|
|
|
|
255
|
|
|
|
229
|
|
Nickel Prices
($/lb)
Source: London Metals Exchange
Nickel Prices
($/lb)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
97
|
|
98
|
|
99
|
|
00
|
|
01
|
|
02
|
|
03
|
|
04
|
|
05
|
|
06
|
|
|
|
|
2.70
|
|
|
|
1.76
|
|
|
|
3.67
|
|
|
|
3.32
|
|
|
|
2.69
|
|
|
|
3.26
|
|
|
|
6.43
|
|
|
|
6.25
|
|
|
|
6.09
|
|
|
|
15.68
|
|
32
Source: Platts Metals Week
Chromium Prices
($/lb)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
97
|
|
98
|
|
99
|
|
00
|
|
01
|
|
02
|
|
03
|
|
04
|
|
05
|
|
06
|
|
|
|
|
0.49
|
|
|
|
0.40
|
|
|
|
0.39
|
|
|
|
0.41
|
|
|
|
0.29
|
|
|
|
0.35
|
|
|
|
0.54
|
|
|
|
0.69
|
|
|
|
0.54
|
|
|
|
0.66
|
|
Molybdenum Oxide
($/lb)
Source: Platts Metals Week
Molybdenum Oxide
($/lb)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
97
|
|
98
|
|
99
|
|
00
|
|
01
|
|
02
|
|
03
|
|
04
|
|
05
|
|
06
|
|
|
|
|
3.69
|
|
|
|
2.57
|
|
|
|
2.56
|
|
|
|
2.23
|
|
|
|
2.36
|
|
|
|
3.26
|
|
|
|
7.26
|
|
|
|
31.24
|
|
|
|
26.58
|
|
|
|
24.78
|
|
33
Operating income increased to $344.3 million for 2006, compared to $149.9 million for 2005.
The benefits of increased sales volume, higher average base-selling prices, gross cost reduction
initiatives, and additional surcharges offset significantly higher LIFO inventory valuation reserve
charges due to higher raw material costs. During 2006, the average cost of our raw materials in our
Flat-Rolled Products segment increased approximately 49% compared to the 2005 average cost. As a
result, for 2006 we recognized a charge of $147.3 million under the LIFO inventory costing
methodology. In 2005, we recorded a LIFO inventory valuation reserve benefit of $8.9 million as a
result of slightly lower raw material costs, compared to 2004.
We continued to aggressively reduce costs and streamline our operations. In 2006, we achieved
gross cost reductions, before the effects of inflation, of approximately $96 million in our
Flat-Rolled Products segment. Major areas of gross cost reductions included $75 million from
operating efficiencies, $11 million from lower compensation and fringe benefit expenses, and $10
million from procurement savings.
To support our strategic growth initiatives in the Flat-Rolled Products segment, we committed
to significantly expand our manufacturing capabilities. In January 2007, we announced expansion of
ATI Allegheny Ludlums titanium and specialty plate facility located in Washington, PA. The
purpose of the capital project is to meet growing demand from the aerospace and defense, chemical
process industry, oil and gas, and electrical energy markets for our Flat-Rolled Products and High
Performance Metals segments. We expect this investment to be approximately $60 million with
completion planned for the second quarter 2008. The titanium and specialty plate capital project
includes increasing reheat furnace, annealing, and flattening capacity at the existing plate mill.
In addition, our plate size capabilities are being expanded and significant productivity
improvements are being made.
In 2006 we also announced the expansion of our STAL joint venture operations in Shanghai,
China. This expansion, which is expected to more than triple STALs precision rolling and slitting
capacity, is estimated to cost approximately $110 million. The expansion is expected to be fully
operational in the 2009 first quarter and is expected to be funded through capital contributions
from the joint venture partners, including a $25 million capital contribution by ATI, bank credit
lines, and the internal cash flow of the joint venture.
2005 Compared to 2004
Sales for the Flat-Rolled Products segment for 2005 were $1.90 billion, or 16% higher than 2004,
due primarily to higher average base-selling prices and higher average raw material surcharges,
partially offset by a decrease in demand in the second half of 2005. Comparative information on the
segments products for the years ended December 31, 2005 and 2004 was:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
For the Years Ended December 31,
|
|
2005
|
|
2004
|
|
% Change
|
|
|
|
Volume (000s lbs.):
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
High value
|
|
|
495,868
|
|
|
|
508,946
|
|
|
|
(3
|
)%
|
|
Commodity
|
|
|
652,870
|
|
|
|
666,560
|
|
|
|
(2
|
)%
|
|
|
|
|
|
Total Flat-Rolled Products
|
|
|
1,148,738
|
|
|
|
1,175,506
|
|
|
|
(2
|
)%
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Average Prices (per lb.):
|
|
|
|
|
|
|
|
|
|
|
|
|
|
High value
|
|
$
|
2.15
|
|
|
$
|
1.67
|
|
|
|
29
|
%
|
|
Commodity
|
|
$
|
1.26
|
|
|
$
|
1.18
|
|
|
|
7
|
%
|
|
Total Flat-Rolled Products
|
|
$
|
1.64
|
|
|
$
|
1.39
|
|
|
|
18
|
%
|
|
|
Our Flat-Rolled Products segment high-value product shipments, which include engineered strip,
Precision Rolled Strip, super stainless steel, nickel alloy, titanium, grain-oriented silicon
electrical steel, and tool steel products, decreased 3%, while average transaction prices for our
high-value products increased 29%, primarily due to product mix. Shipments declined primarily due
to softness in automotive markets partially offset by strong capital goods and power generation
markets, especially in Asia. Our direct international sales, which were primarily comprised of high
value products, increased $138.6 million to $350.9 million, and represented a record 18.5% of sales
for the Flat-Rolled Products segment.
34
Shipments of commodity products (including stainless steel hot roll and cold roll sheet, and
stainless steel plate, among other products) decreased 2% and average transaction prices for these
products increased 7%. The decrease in shipments was primarily attributable to inventory
adjustments in the second half of 2005 by service center customers primarily for stainless steel
sheet. In 2005, consumption in the U.S. of stainless steel strip, sheet and plate products
decreased approximately 10%, compared to 2004 consumption, according to the Specialty Steel
Institute of North America (SSINA). Demand from the capital goods markets such as chemical
processing, oil and gas, and power generation markets remained strong throughout 2005. We
experienced a weakening in demand from the automotive, construction and mining, and appliances
markets.
Operating income increased to $149.9 million for 2005 compared to $61.5 million in the 2004
period. The benefits of higher average base-selling prices, cost reduction initiatives, additional
surcharges, and a change in the LIFO inventory valuation reserve due to lower raw material costs,
were partially offset by lower shipments and higher energy costs. During 2005, the average cost of
our raw materials in our Flat-Rolled Products segment decreased approximately 9% compared to the
2004 average cost. This compares to an increase of approximately 50% in 2004, compared to 2003. As
a result, for 2005 we recognized a benefit of $8.9 million under the LIFO inventory costing
methodology. In 2004, we recorded a LIFO inventory valuation reserve charge of approximately $86.5
million as a result of the higher raw material costs. Natural gas and electricity costs, net of
natural gas hedges, for 2005 were approximately $39.5 million higher than 2004.
We continued to aggressively reduce costs and streamline our operations. In 2005, we achieved
gross cost reductions, before the effects of inflation, of approximately $85 million in our
Flat-Rolled Products segment. Major areas of gross cost reductions included $24 million from
operating efficiencies, $49 million from procurement, and $12 million from lower compensation and
fringe benefit expenses. At the end of 2005, we decided to indefinitely idle the West Leechburg, PA
flat-rolled products finishing facility, which occurred in stages during 2006. These restructuring
charges of $17.5 million, plus charges of $8.5 million for fair market value adjustments of
previously recognized asset impairments, are excluded from 2005 segment operating profit.
In 2005, we announced $16 million in strategic capital programs to expand our titanium and
nickel-based alloy and specialty alloy production capabilities which include expanding high-value
plate products capacity by 25%, upgrading our flat-rolled cold-rolling assets used to produce
titanium sheet and strip products, and expanding premium product re-melting capacity. These
projects are expected to be fully implemented in 2007.
Acquisition of J&L Specialty Steel LLC Assets
On June 1, 2004, we completed the acquisition of substantially all of the assets of J&L Specialty
Steel LLC, a producer of flat-rolled stainless steel products with operations in Midland,
Pennsylvania and Louisville, Ohio, for $69.0 million in total consideration, including the
assumption of certain current liabilities. The purchase price included $7.5 million cash paid at
closing, the issuance to the seller of a non-interest bearing $7.5 million promissory note paid on
June 1, 2005, and the issuance to the seller of a promissory note in the principal amount of $54.0
million, which is subject to final adjustment, and secured by the property, plant and equipment
acquired, payable in installments in 2007 through 2011, which bears interest at a London Inter-bank
Offered Rate plus a 1% margin, with a maximum interest rate of 6%.
In connection with the J&L asset acquisition, in June 2004 we reached a labor agreement with
the USW, which represents employees at Allegheny Ludlum and at the former J&L facilities. The
agreement provided for a workforce restructuring through which we are achieving significant
productivity improvements. Through a reduction in the number of job classifications and the
implementation of flexible work rules, employees have been given broader responsibilities and the
opportunity to become more involved in the business. The number of production and maintenance
employees at the pre-acquisition Allegheny Ludlum facilities was reduced by 650 employees, or
approximately 25%, through an early retirement program over two and a half years pursuant to which
the employees were offered transition incentives. Approximately 40% of these retirements occurred
in second half of 2004, with over 70% of these retirements having taken place by the end of 2005,
and 100% of these retirements were effective by the end of 2006.
The
acquisition of the J&L assets and the negotiation of the
progressive labor agreement in 2004
with the USW have continued to improve the performance of our Allegheny Ludlum business.
35
Engineered Products
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(In millions)
|
|
2006
|
|
% Change
|
|
2005
|
|
% Change
|
|
2004
|
|
|
|
Sales to external customers
|
|
$
|
432.7
|
|
|
|
10
|
%
|
|
$
|
393.4
|
|
|
|
33
|
%
|
|
$
|
295.0
|
|
|
|
|
Operating profit
|
|
|
56.7
|
|
|
|
19
|
%
|
|
|
47.5
|
|
|
|
128
|
%
|
|
|
20.8
|
|
|
|
|
Operating profit as a percentage of sales
|
|
|
13.1
|
%
|
|
|
|
|
|
|
12.1
|
%
|
|
|
|
|
|
|
7.1
|
%
|
|
|
|
Direct international sales as a percentage of sales
|
|
|
26.8
|
%
|
|
|
|
|
|
|
28.6
|
%
|
|
|
|
|
|
|
28.9
|
%
|
|
|
Our Engineered Products segment includes the production of tungsten powder, tungsten heavy
alloys, tungsten carbide materials and carbide cutting tools. The segment also produces carbon
alloy steel impression die forgings, and large grey and ductile iron castings, and provides
precision metals processing services. The operations in this segment are ATI Metalworking Products,
ATI Portland Forge, ATI Casting Service and Rome Metals. On April 5, 2005, we acquired U.K.-based
Garryson Limited (Garryson), a leading producer of tungsten carbide burrs, rotary tooling and
specialty abrasive wheels and discs. The acquisition was accounted for as a purchase, and our
results for ATI Metalworking Products include Garrysons sales and earnings from the acquisition
date.
The major markets served by our products of the Engineered Products Segment include a wide
variety of industrial markets including automotive, chemical process
industry, oil and gas, machine and
cutting tools, construction and mining, aerospace, transportation, and wind power generation.
2006 Compared to 2005
Sales for the Engineered Products segment in 2006 increased 10%, to $432.7 million, and operating
profit increased 19%, to $56.7 million, both compared to 2005. Demand for our tungsten products was
strong from the oil and gas, construction and mining, aerospace and defense, and power generation
markets. Demand was strong for our forged products from the transportation, construction and
mining, and oil and gas markets. Demand for our cast products was strong from the wind energy, and
transportation markets. Demand remained very strong for our titanium precision metal processing
conversion services.
The improvement in segment sales was primarily due to higher selling prices and increased
volume, including shipments from our U.K.-based ATI Garryson Limited cutting tool operations
acquired in April 2005. Segment operating profit improved to $56.7 million in 2006, principally as
a result of improved pricing and the benefits of cost reductions, which totaled $8.2 million. This
improvement in operating profit was partially offset by the negative impact of higher raw material
costs especially in the second half of the 2006 year. Operating profit included a LIFO inventory
valuation reserve charge of $0.3 million in 2006 and a charge of $8.7 million in 2005 as a result
of higher raw material costs and inventory levels.
In 2006, we continued to invest to enhance our manufacturing capabilities and reduce costs. In
the 2005 fourth quarter, we began a $17 million capital investment to expand our production
capacity to internally source all of our ammonium paratungstate (APT) and cobalt requirements at
what is expected to be significantly lower costs than purchased material. In addition, in 2006, we
invested $4 million to expand our titanium precision metal conversion services operation as part
our continuing strategic program to increase our overall titanium production capacity to better
meet growing global demand.
2005 Compared to 2004
Sales for the Engineered Products segment in 2005 increased 33%, to $393.4 million, and operating
profit increased 128%, to $47.5 million, both compared to 2004. Demand for our tungsten products
was strong from the oil and gas, mining, and automotive markets. Demand remained strong for
forgings from the Class 8 truck, and construction and mining markets. Demand for our cast products
was strong from the transportation and wind energy markets. Demand was very strong for our titanium
precision metal processing conversion services.
The improvement in segment sales was primarily due to higher selling prices and increased
volume, including shipments from our U.K.-based ATI Garryson Limited cutting tool operations
acquired in April 2005. Segment operating profit improved to $47.5 million in 2005, principally as
a result of improved pricing and the benefits of cost reductions, which totaled $6.9 million.
Operating profit included a LIFO inventory valuation reserve charge of
36
$8.7 million in 2005 and a charge of $9.5 million in 2004 as a result of higher raw material
costs and inventory levels.
Corporate Expenses
Corporate expenses were 1.4% of sales, or $68.9 million, in 2006 compared to 1.5% of sales, or
$51.7 million, in 2005 and 1.3% of sales, or $34.9 million, in 2004. The increase in corporate
expenses in 2006 and 2005 was primarily the result of expenses associated with annual and long-term
performance-based incentive compensation programs, partially offset by cost controls.
Interest Expense, net
Interest expense, net of interest income, was $23.3 million for 2006 compared to $38.6 million for
2005, and $35.5 million for 2004. Interest expense is presented net of interest income of $15.0
million for 2006, $8.4 million for 2005, and $2.9 million for 2004. The increase in interest income
for 2006 and 2005 primarily results from higher cash balances.
Increased capital expenditures associated with strategic investments to expand our production
capabilities resulted in higher interest capitalization in 2006. Interest expense in 2006, 2005,
and 2004 was reduced by $4.5 million, $0.2 million, and $0.9 million, respectively, related to
interest capitalization on capital projects.
In prior years, we entered into receive fixed, pay floating interest rate swap contracts
related to our $300 million, 8.375% 10-year Notes. In 2004, we terminated the remaining
outstanding swap agreements and recognized a gain. The settlement gain is being amortized into
income as an offset to interest expense over the remaining life of the 10-year Notes. Interest
expense decreased by $1.7 million in 2006, $1.5 million in 2005, and $4.4 million in 2004 due to
these settled interest rate swap agreements.
Restructuring Costs and Curtailment Gain
We had no restructuring costs or curtailment gains in 2006. We recorded restructuring costs of
$23.9 million in 2005 and a curtailment gain, net of restructuring costs, of $40.4 million in 2004.
In 2005, we recorded a restructuring charge of $23.9 million primarily related to recognizing
an asset impairment charge for certain long-lived assets in the Flat-Rolled Products segment. At
the end of 2005, we decided to indefinitely idle Allegheny Ludlums West Leechburg, PA flat-rolled
products finishing facility. The cost of indefinitely idling the facility was $17.3 million. The
2005 restructuring charge also included adjustments of previously recognized asset impairment
charges for changes in estimated fair market values. We recorded $8.5 million of asset impairment
charges associated with previously idled assets in the Flat-Rolled Products segment at the
Washington Flat-Roll coil facility located in Washington, PA, and at the stainless steel plate
facility located in Massillon, OH, partially offset by a $1.9 million reversal of previously
recorded lease termination charges.
In 2004, the curtailment gain, net of restructuring costs, of $40.4 million, includes the
$71.5 million curtailment and settlement gain and the $25.3 million pension termination benefit
charge discussed in Retirement Benefit Expense, below, and $5.8 million of restructuring charges.
The restructuring charges related to the 2004 labor agreement at our Allegheny Ludlum operations and
the J&L asset acquisition, and included labor agreement costs of $4.6 million, severance costs of
$0.7 million related to approximately 30 salaried employees, and $0.5 million for asset impairment
charges for redundant equipment following the J&L asset acquisition.
At December 31, 2006, approximately $3 million of prior year workforce reduction and
facility closure charges are future cash requirements that will be paid over the next several
years. Cash to meet these obligations is expected to be paid from internally generated funds from
operations.
Other Expenses, Net of Gains on Asset Sales
Other expenses, net of gains on asset sales, includes charges incurred in connection with closed
operations, pretax gains and losses on the sale of surplus real estate, non-strategic investments
and other assets, operating results from
37
equity-method investees, minority interest, and other non-operating income or expense. These items
are presented primarily in selling and administrative expenses, and in other income (expense) in
the statement of income and resulted in net charges of $15.2 million in 2006 and $33.8 million in
2005, and other income of $2.5 million in 2004.
Other expenses for 2006 primarily related to legal costs associated with closed operations.
For 2005, other expenses included $26.8 million for legal matters and $7.0 million for
environmental and other closed company costs. The charges for legal matters included the settlement
of the Kaiser Aerospace & Electronics matter, the unfavorable court judgment rendered in April 2005
concerning a commercial dispute with a raw materials supplier, both of which were paid in 2006, and
other matters associated with closed companies, and are classified in selling and administrative
expenses in the consolidated statement of income.
Retirement Benefit Expense
Retirement benefit expense, which primarily includes pension and postretirement medical benefits,
increased $4.3 million in 2006 due to the use of a lower assumed discount rate to value obligations
and a lower level of postretirement medical benefit plan assets. In 2005 and 2004, retirement
benefit expense declined, compared to the applicable preceding full year period, primarily as a
result of higher than expected returns on pension assets during 2004 and 2003, actions taken in the
second quarter 2004 to control retiree medical costs, and the favorable impact of the Medicare
prescription drug legislation, partially offset by the use of progressively lower discount rate
assumptions for determining benefit plan liabilities. Retirement benefit expense, excluding the
effect of curtailment gains and termination benefit charges, was $81.9 million for 2006, $77.6
million for 2005, and $119.8 million for 2004. The effect of the Medicare prescription drug
legislation, which provides for a Federal subsidy to sponsors of retiree health care benefit plans
that provide a benefit that is at least actuarially equivalent to the benefit established by law,
is recognized in operating results over a number of years. Retirement benefit expenses are included
in both cost of sales and selling and administrative expenses. Retirement benefit expense included
in cost of sales and selling and administrative expenses for the years ended 2006, 2005 and 2004
was as follows:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(In millions)
|
|
2006
|
|
2005
|
|
2004
|
|
|
|
Cost of sales
|
|
$
|
55.3
|
|
|
$
|
55.1
|
|
|
$
|
88.4
|
|
|
Selling and administrative expenses
|
|
|
26.6
|
|
|
|
22.5
|
|
|
|
31.4
|
|
|
|
|
Total retirement benefit expense
|
|
$
|
81.9
|
|
|
$
|
77.6
|
|
|
$
|
119.8
|
|
|
|
The 2004 retirement benefit expense shown above does not include the effects of the $71.5
million curtailment and settlement gain related to the elimination of retiree medical benefits for
certain non-collectively bargained employees beginning in 2010, nor does this expense include the
$25.3 million charge related to the Transition Assistance Program (TAP) incentives associated
with the 2004 labor agreement at Allegheny Ludlum, which was paid from our U.S. qualified defined
benefit pension plan.
Total retirement benefit expense for 2007 is expected to be approximately $32 million, with
effects on cost of sales and selling and administrative expenses similar to the percentages in
2006. Pension expense for 2007 is expected to be approximately $17 million, compared to $64 million
in 2006, as higher than expected returns on pension assets in 2006 and the positive benefits of the
voluntary $100 million 2006 pension contribution are partially offset by the use of a lower assumed
discount rate to value pension liabilities. Postretirement medical expense for 2007 is expected to
decrease to approximately $15 million, from $18 million in 2006, as higher than expected returns on
plan assets in 2006 is partially offset by the use of a lower assumed discount rate to value
obligations.
Income Taxes
Results of operations for 2006 included a provision for income taxes of $297.3 million, or 34.2% of
income before tax, for U.S. Federal, foreign and state income taxes. The results for 2006
benefited from a favorable $8.7 million adjustment of prior years taxes. For 2005, results of
operations included an income tax benefit of $54.7 million principally related to the reversal of
the remaining valuation allowance for our U.S. Federal net deferred tax assets, partially offset by
accruals for U.S. Federal, foreign and state income taxes. Results of operations for 2004 did not
include an income tax provision or benefit for current or deferred taxes primarily as a result of
the uncertainty regarding full utilization of the net deferred tax asset and available operating
loss carryforwards. From the 2003 fourth quarter through the third quarter of 2005, we maintained a
valuation allowance for a major portion of our U.S.
38
Federal deferred tax assets and certain state deferred tax assets in accordance with SFAS No. 109,
Accounting for Income Taxes, due to uncertainty regarding full utilization of our net deferred
tax asset, including the 2003 and 2004 unutilized net operating losses. In the 2003 fourth quarter
we had recorded a $138.5 million valuation allowance for the majority of our net deferred tax
asset, based upon the results of our quarterly evaluation concerning the estimated probability that
the net deferred tax asset would be realizable in light of our history of annual reported losses in
the years 2001 through 2003. In 2005, we generated taxable income which exceeded the 2003 and 2004
net operating losses allowing us to fully realize these U.S. Federal tax benefits. This realization
of tax benefits, together with our improved profitability, required us to eliminate the remaining
valuation allowance for U.S. Federal income taxes in the 2005 fourth quarter. In 2004, we received
$7.2 million in income tax refunds related to carrying back the previous years taxable loss to
earlier years in which we had paid taxes.
Deferred taxes result from temporary differences in the recognition of income and expense for
financial and income tax reporting purposes, and differences between the fair value of assets
acquired in business combinations accounted for as purchases for financial reporting purposes and
their corresponding tax bases. Deferred income taxes represent future tax benefits or costs to be
recognized when those temporary differences reverse. At December 31, 2006, we had a net deferred
tax asset of $151.4 million. A significant portion of our deferred tax assets relates to the
postretirement benefit obligations, which have been recorded in the accompanying financial
statements but which are not recognized for income tax reporting purposes until the benefits are
paid. These benefit payments are expected to occur over an extended period of years.
Financial Condition and Liquidity
We believe that internally generated funds, current cash on hand, and available borrowings under
existing secured credit lines will be adequate to meet foreseeable liquidity needs, including a
substantial expansion of our production capabilities over the next few years. We did not borrow
funds under our domestic secured credit facility during 2006, 2005, or 2004. However, a portion of
this secured credit facility is utilized to support letters of credit.
Our ability to access the credit markets in the future to obtain additional financing, if
needed, may be influenced by our credit rating. As of December 31, 2006, Standard & Poors Ratings
Services corporate credit rating for our Company was BB with a stable outlook. As of December 31,
2006, Moodys Investor Services corporate family rating for our Company was Ba2 with a stable
outlook. Changes in our credit rating do not impact our access to, or the cost of, our existing
credit facilities.
We have no off-balance sheet financing relationships with variable interest or structured
finance entities.
Cash Flow and Working Capital
In 2006, cash generated by operations of $408.5 million, the proceeds from exercises of stock
options of $33.1 million, and tax benefits on share-based compensation of $80.9 million were used
to invest $235.2 million in capital equipment, fund a $100 million voluntary contribution to our
U.S. qualified defined benefit pension plan, pay dividends of $43.1 million, repay debt of $7.1
million, and increase cash balances by $139.6 million to $502.3 million at December 31, 2006. In
2005, cash generated by operations of $322.6 million, the proceeds from exercises of stock options
of $26.1 million, and tax benefits on share-based compensation of $25.2 million were used to invest
$90.1 million in capital equipment, fund a $100 million voluntary contribution to our U.S.
qualified defined benefit pension plan, pay $18.3 million for the acquisition of the Garryson
Limited operation, repay debt of $25.7 million, pay dividends of $27.1 million, and increase cash
balances by $111.9 million to $362.7 million at December 31, 2005. In 2004, cash generated from
operations of $74.1 million, proceeds from sale of common stock of $229.7 million, proceeds from
asset sales of $6.6 million, and proceeds from exercises of stock options of $7.6 million, were
used to invest $49.9 million in capital equipment, fund a $50 million voluntary contribution to our U.S.
defined benefit pension plan, pay $7.5 million of the purchase price for the J&L assets, repay debt
of $15.9 million, pay dividends of $21.2 million, and increase cash balances by $171.2 million to
$250.8 million at December 31, 2004. We use cash flow from operations before voluntary pension plan
contributions in order to evaluate and compare fiscal periods that do not include these
contributions, and to make resource allocation decisions among operational requirements, investing
and financing alternatives.
39
Managed Working Capital
($ millions)
Managed Working Capital
($ millions)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
01
|
|
02
|
|
03
|
|
04
|
|
05
|
|
06
|
|
Millions/$
|
|
|
719
|
|
|
|
564
|
|
|
|
576
|
|
|
|
853
|
|
|
|
1,048
|
|
|
|
1,582
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
% of Annualized Revenue
|
|
|
36.8
|
%
|
|
|
32.4
|
%
|
|
|
30.7
|
%
|
|
|
29.5
|
%
|
|
|
30.3
|
%
|
|
|
29.0
|
%
|
The favorable impact of improved operating results in 2006 and 2005 on cash flow from
operations was offset by continuing investment in managed working capital to support the higher
business levels and the effect of higher costs for certain raw materials. As part of managing the
liquidity of the business, we focus on controlling inventory, accounts receivable and accounts
payable. In measuring performance in controlling this managed working capital, we exclude the
effects of the LIFO inventory valuation reserves, excess and obsolete inventory reserves, and
reserves for uncollectible accounts receivable which, due to their nature, are managed separately.
During 2006, managed working capital, which we define as gross inventory plus accounts receivable
less accounts payable, increased $534.2 million. This increase resulted from a $166.5 million
increase in accounts receivable due to a higher level of sales in the fourth quarter 2006 compared
to the fourth quarter 2005, and a $409.2 million increase in inventory, mostly as a result of
increased operating volumes and higher raw material costs, partially offset by a $41.5 million
increase in accounts payable. Most of the increase in raw materials is expected to be recovered
through surcharge and index pricing mechanisms. During 2005, managed working capital increased by
$187.8 million, excluding working capital acquired as part of the Garryson Limited acquisition.
This increase in managed working capital resulted from a $80.9 million increase in accounts
receivable due to a higher level of sales in the 2005 fourth quarter compared to the fourth quarter
of 2004, and a $145.6 million increase in inventory mostly as a result of higher costs for certain
raw materials and increased business volumes, partially offset by a $38.7 million increase in
accounts payable. Managed working capital has increased $1.0 billion over the past four years as
our level of business activity has significantly increased and raw material costs have increased.
This increase in managed working capital is expected to represent a future source of cash if the
level of business activity were to decline. Managed working capital as a percent of annualized
sales declined to 29.0% at the end of 2006, compared to 30.3% at the end of 2005, 29.5% in 2004,
and 30.7% in 2003. The decrease in 2006 of managed working capital
40
as a percentage of sales was primarily due to higher business activity in the Flat-Rolled
Products segment, which has a shorter manufacturing cycle than our other business segments, and ATI
Business System initiatives. While inventory and accounts receivable balances increased during this
four year period, gross inventory turns, which exclude the effect of LIFO inventory valuation
reserves, decreased slightly in 2006 after improving for the past three years, and days sales
outstanding, which measures actual collection timing for accounts receivable, has steadily
improved.
The components of managed working capital were as follows:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
December 31,
|
|
|
December 31,
|
|
|
December 31,
|
|
|
(In millions)
|
|
2006
|
|
|
2005
|
|
|
2004
|
|
|
|
|
Accounts receivable, net
|
|
$
|
610.9
|
|
|
$
|
442.1
|
|
|
$
|
357.9
|
|
|
Inventory, net
|
|
|
798.7
|
|
|
|
607.1
|
|
|
|
513.0
|
|
|
Accounts payable
|
|
|
(355.1
|
)
|
|
|
(312.9
|
)
|
|
|
(271.2
|
)
|
|
|
|
Subtotal
|
|
|
1,054.5
|
|
|
|
736.3
|
|
|
|
599.7
|
|
|
Allowance for doubtful accounts
|
|
|
5.7
|
|
|
|
8.1
|
|
|
|
8.4
|
|
|
LIFO reserve
|
|
|
466.7
|
|
|
|
269.7
|
|
|
|
223.9
|
|
|
Corporate and other
|
|
|
55.3
|
|
|
|
33.9
|
|
|
|
20.6
|
|
|
|
|
Managed working capital
|
|
$
|
1,582.2
|
|
|
$
|
1,048.0
|
|
|
$
|
852.6
|
|
|
|
|
Annualized prior 2 months sales
|
|
$
|
5,453.5
|
|
|
$
|
3,461.1
|
|
|
$
|
2,887.0
|
|
|
|
|
Managed working capital as a % of sales
|
|
|
29.0
|
%
|
|
|
30.3
|
%
|
|
|
29.5
|
%
|
|
|
Capital expenditures for 2006 were $235.2 million, compared to $90.1 million in 2005 and $49.9
million for 2004.
We have committed to significantly expand our manufacturing capabilities to meet current and
expected demand growth from the aerospace (engine and airframe), defense, chemical process
industry, oil and gas, and medical markets, especially for titanium and titanium-based alloys,
nickel-based alloys and superalloys, and specialty alloys. Our self-funded investments include the
following announced projects:
|
§
|
|
A multi-phase titanium products expansion that is expected to yield 44 million
pounds of aerospace quality titanium sponge annual capacity and increase ATIs annual titanium
melt capacity by at least 25 million pounds. The four-phase expansion, which is expected to
total approximately $625 million, includes the following:
|
|
|
|
|
The Phase I expansion of ATIs titanium production capabilities was announced in July
2005, and includes upgrading and restarting ATIs titanium sponge facility in Albany, OR,
constructing a third Plasma Arc Melt (PAM) cold-hearth furnace in Bakers, NC, adding three
vacuum arc remelt (VAR) furnaces, expanding high-value plate products capacity by 25%, and
continued upgrading of ATIs cold-rolling assets used in producing titanium sheet and
strip products. Phase I of our Albany, OR titanium sponge facility is now fully
operational with six new furnaces producing at an annualized rate of approximately 8.0
million pounds, and the additional VAR melt capacity began operations in late 2006 and
early 2007. The new PAM furnace is expected to begin operations in the first quarter
2007. Plasma arc melting is a superior cold-hearth melting process for making alloyed
titanium products for jet engine rotating parts, medical applications, and other critical
applications. VAR melting is a consumable electrode re-melting process that improves the
cleanliness and chemical homogeneity of the alloys.
|
|
|
|
|
|
|
The Phase II expansion of ATIs titanium production capabilities was announced in
March 2006, and includes additional titanium sponge capacity at ATIs facility in Albany,
OR, and an additional VAR furnace at ATIs facility in Bakers, NC. We expect the
additional titanium sponge production capacity of approximately 4.0 million pounds
annually from this phase to begin operation in the first half of 2007. The additional VAR
melt capacity is expected to begin operation early in the third quarter 2007.
|
|
|
|
|
|
|
The Phase III expansion of ATIs titanium production capabilities was announced in
June 2006, and includes additional titanium sponge capacity and an additional VAR furnace
at ATIs facility in Albany, OR. The additional titanium sponge production capacity of
approximately 4.0 million pounds annually from this phase is expected to be fully
operational in the second half of 2007. As a result of Phases I, II and III, we expect
our annual titanium sponge production capacity from the Albany facility to be
approximately
|
41
|
|
|
|
12 million pounds in 2007, expanding to approximately 16 million pounds in 2008. The
additional VAR melt capacity is expected to begin operations in two stages, with the first
start-up in the second quarter of 2007 and the second stage in the first quarter of 2008.
|
|
|
|
|
|
|
In June 2006, we announced the Phase IV
expansion to our titanium capabilities. Phase IV is a greenfield premium-grade titanium
sponge facility to be built in Rowley, UT with an annual capacity of 24 million pounds.
This investment, which is estimated at $425 to $450 million including engineering and design for
future expansion, is aimed at increasing our capacity to produce titanium alloys for
aerospace and defense applications. Premium-grade sponge is essential for many aerospace
applications, including rotating quality titanium alloys used for new jet engines and
spare parts. ATI expects initial production of titanium sponge to begin in the third
quarter 2008, and grow to an initial annualized rate of 24 million pounds in 2009.
|
|
|
|
|
|
|
In February 2007, we announced a further expansion of our Albany, OR titanium sponge
production capabilities. The additional expansion of the Albany, OR facility will include
four sponge furnaces and related processing operations, and is expected to be in service in
the first half of 2008. This expansion is expected to add another 4 million pounds of
titanium sponge capacity annually.
|
|
|
|
|
Upon the completion of these phases, our internal titanium sponge annual capacity of approximately
44 million pounds will be in addition to the amount of titanium sponge and titanium scrap that we
purchase from external sources.
|
|
§
|
|
In January 2007, we announced the expansion of our titanium and nickel-based
superalloy capabilities at facilities located in Bakers, NC. The total investment is
approximately $215 million, which is expected to be nearly evenly spread over the next three
years and be substantially completed by the end of 2009. The project will include:
|
|
|
|
|
Additional forging capacity. We plan to add an integrated 10,000 ton press forge,
700mm rotary forge, conditioning, finishing, and inspection facility to support increased
forged product requirements. The new forging capacity is expected to be operational by
the third quarter 2009. Forging is a hot-forming process that produces wrought forging
billet and forged machining bar from an ingot.
|
|
|
|
|
|
|
A fourth PAM to support premium titanium alloy growth requirements. We expect this
fourth PAM furnace to begin production by the fourth quarter 2008.
|
|
|
|
|
|
|
Additional VAR capacity to support premium nickel-based superalloy and titanium
growth. We expect one new VAR to be in production in the first quarter 2008. The
remaining four VAR furnaces would be installed as needed.
|
|
§
|
|
A $60 million expansion of our titanium and specialty plate facility located in
Washington, PA, which is expected to be completed in the second quarter 2008. In addition to
titanium and titanium alloys, ATIs specialty plate products include duplex alloys,
superaustenitic alloys, nickel-based alloys, zirconium alloys, armor plate, and common
austenitic stainless grades. Plate is a flat-rolled mill product that is 3/16 inch (4.76 mm)
thick, or greater, and over 10 inches (254 mm) wide. The project will include:
|
|
|
|
|
Increasing reheat furnace, annealing, and flattening capacity at ATIs existing plate
mill.
|
|
|
|
|
|
|
In addition, ATIs plate size capabilities are being expanded and significant
productivity improvements are being made.
|
|
§
|
|
A $30 million expansion of our premium-melt nickel-based alloy, superalloy, and
specialty alloy production capabilities to our capacity to produce these high performance
alloys used for aero-engine rotating parts, airframe applications, oil and gas exploration,
extraction and refining, power generation land-based turbines and flue gas desulfurization
pollution control units, which was completed in early 2007. Major projects of this expansion,
which increased our premium-melt capacity by approximately 20%, included:
|
42
|
|
|
|
Upgrading and expanding vacuum induction melt (VIM) capacity. VIM is a melting
process designed for premium grades with high alloy content that require more precise
chemistry control and lower impurity levels.
|
|
|
|
|
|
|
Installation of two new electro-slag re-melt (ESR) furnaces and three new VAR
furnaces. ESR and VAR furnaces are consumable electrode re-melting processes used to
improve both the cleanliness and metallurgical structure of alloys.
|
The above-described strategic growth capital projects represent approximately $925 million of
self-funded capital investments, approximately $145 million of which had already been expended
through 2006. We expect that our projected 2007 capital expenditures will be between $450 to $500
million, including $300 to $330 million for the above-mentioned strategic capital projects. The
remaining $450 to $480 million of the $925 million of strategic growth capital projects will be
expended in 2008 and 2009, with the majority of the expenditures expected in 2008.
Additionally, STAL, our Chinese joint venture company in which ATI has a 60% interest,
commenced an expansion of its operations in Shanghai, China in late 2006. This expansion, which is
expected to more than triple STALs precision rolling and slitting capacity, is estimated to cost
approximately $110 million. The expansion is expected to be fully operational in the 2009 first
quarter and is expected to be funded through capital contributions from the joint venture partners,
bank credit lines, and the internal cash flow of the joint venture. Our cash contribution to this
expansion is expected to be approximately $25 million, of which $12.4 million was contributed by
ATI in the 2006 third quarter with the remainder anticipated to be contributed in the first half of
2007. The financial results of STAL are consolidated into our financial statements with the 40%
interest of our minority partner recognized as other income or expense in the statements of income
and as a liability in the statements of financial position.
Debt
Total debt outstanding decreased $6.8 million, to $553.6 million at December 31, 2006, from $560.4
million at December 31, 2005. The decrease was primarily related to capital leases and financing on
certain capital projects. In managing our overall capital structure, one of the measures on which
we focus is net debt to total capitalization, which is the percentage of our debt, net of cash on
hand, to our total invested and borrowed capital. In determining this measure, debt and total
capitalization are net of cash on hand which may be available to reduce borrowings. Our net debt to
total capitalization ratio improved to 3.3% at December 31, 2006, from 19.8% at December 31, 2005,
and 43.8% at December 31, 2004. The lower ratio in 2006 results primarily from a continued increase
in cash on hand and stockholders equity resulting from the improvement in results of operations.
|
|
|
|
|
|
|
|
|
|
|
|
|
December 31,
|
|
|
December 31,
|
|
|
(In millions)
|
|
2006
|
|
|
2005
|
|
|
|
|
Total debt
|
|
$
|
553.6
|
|
|
$
|
560.4
|
|
|
Less: Cash
|
|
|
(502.3
|
)
|
|
|
(362.7
|
)
|
|
|
|
Net debt
|
|
$
|
51.3
|
|
|
$
|
197.7
|
|
|
|
|
|
|
|
|
|
|
|
|
Net debt
|
|
$
|
51.3
|
|
|
$
|
197.7
|
|
|
Total stockholders equity
|
|
|
1,492.6
|
|
|
|
799.9
|
|
|
|
|
Total capital
|
|
$
|
1,543.9
|
|
|
$
|
997.6
|
|
|
Net debt to capital ratio
|
|
|
3.3
|
%
|
|
|
19.8
|
%
|
|
|
We maintain a senior secured domestic revolving credit facility which is secured by all
accounts receivable and inventory of our U.S. operations and includes capacity for up to $175
million of letters of credit. Under the facility, if undrawn availability, as defined in the
facility, were to decline below $75 million, corporate actions that could be undertaken without the
prior consent of the lending group, including capital expenditures, acquisitions, sales of assets,
dividends, investments in, or loans to, corporations, partnerships, joint ventures and
subsidiaries, issuance of unsecured indebtedness, leases, and prepayment of indebtedness, would be
limited. The amended facility contains a financial covenant, which is not measured unless our
undrawn availability is less than $75 million. This financial covenant, when measured, requires us
to prospectively maintain a ratio of consolidated earnings before interest, taxes, depreciation and
amortization (as defined in the credit facility) to fixed charges of at least 1.0 to 1.0 from the
date the covenant is measured. Our ability to borrow under the amended secured credit facility in
the future could be
43
adversely affected if we fail to maintain the applicable covenants under the agreement
governing the facility. At December 31, 2006, we had the ability to access the entire $325 million
undrawn availability under the facility, and the measurement of the financial covenant described
above was 5.0 to 1.0.
Interest rate swap contracts have been used from time-to-time to manage our exposure to
interest rate risks. At December 31, 2006, we have no interest rate swap contracts in place. We
have deferred gains on settled receive fixed, pay floating interest rate swap contracts
associated with our $300 million, 8.375% Notes due 2011 (Notes). These gains on settlement, which
occurred in 2004 and 2003, remain a component of the reported balance of the Notes, and are ratably
recognized as a reduction to interest expense over the remaining life of the Notes, which is
approximately five years. At December 31, 2006, the deferred settlement gain was $10.5 million. The
result of the receive fixed, pay floating arrangements was a decrease in interest expense of $1.7
million, $1.5 million and $4.4 million for the years ended December 31, 2006, 2005 and 2004,
respectively, compared to the fixed interest expense of the ten-year Notes.
A summary of required payments under financial instruments (excluding accrued interest) and
other commitments are presented below.
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Less than
|
|
|
1-3
|
|
|
4-5
|
|
|
After 5
|
|
|
(In millions)
|
|
Total
|
|
|
1 year
|
|
|
years
|
|
|
years
|
|
|
years
|
|
|
|
|
Contractual Cash Obligations
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total Debt including Capital Leases
|
|
$
|
547.1
|
|
|
$
|
23.7
|
|
|
$
|
27.0
|
|
|
$
|
340.1
|
|
|
$
|
156.3
|
|
|
Operating Lease Obligations
|
|
|
51.6
|
|
|
|
17.0
|
|
|
|
18.2
|
|
|
|
10.1
|
|
|
|
6.3
|
|
|
Other Long-term Liabilities (A)
|
|
|
149.8
|
|
|
|
|
|
|
|
75.9
|
|
|
|
7.6
|
|
|
|
66.3
|
|
|
Unconditional Purchase Obligations
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Raw materials (B)
|
|
|
1,765.4
|
|
|
|
733.4
|
|
|
|
717.5
|
|
|
|
314.5
|
|
|
|
|
|
|
Capital expenditures
|
|
|
37.1
|
|
|
|
36.5
|
|
|
|
0.6
|
|
|
|
|
|
|
|
|
|
|
Other (C)
|
|
|
30.5
|
|
|
|
18.1
|
|
|
|
9.8
|
|
|
|
2.0
|
|
|
|
0.6
|
|
|
|
|
Total
|
|
$
|
2,581.5
|
|
|
$
|
828.7
|
|
|
$
|
849.0
|
|
|
$
|
674.3
|
|
|
$
|
229.5
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(In millions)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Other Financial Commitments
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Lines of Credit (D)
|
|
$
|
395.7
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|
|
$
|
45.0
|
|
|
$
|
|
|
|
$
|
350.7
|
|
|
$
|
|
|
|
Guarantees
|
|
|
17.2
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(A) Other long-term liabilities exclude pension liabilities and accrued postretirement
benefits.
(B) We have contracted for physical delivery for certain of our raw materials to meet a
portion of our needs. These contracts are based upon fixed or variable price provisions. We used
current market prices as of December 31, 2006, for raw material obligations with variable pricing.
(C) We have various contractual obligations that extend through 2015 for services involving
production facilities and administrative operations. Our purchase obligation as disclosed
represents the estimated termination fees payable if we were to exit these contracts.
(D) Drawn amounts, if any, are included in total debt. There are no drawn amounts at December
31, 2006. Includes $119.5 million utilized under the $325 million domestic secured credit facility
for standby letters of credit, which renew annually and are used to support: $72.5 million of
financing outside of the domestic secured credit facility, primarily for our foreign-based
operations; $38.5 million in workers compensation and general insurance arrangements; and $8.5
million related to legal, environmental and other matters.
Retirement Benefits
We adopted Statement of Financial Accounting Standards No. 158, Employers Accounting for Defined
Benefit Pension and Other Postretirement Plans (FAS 158) on December 31, 2006. FAS 158 requires
that the net funded position of the plans, as measured by the projected benefit obligation (PBO)
in the case of pension plans, and by the accumulated postretirement benefit obligation (APBO) in
the case of other postretirement benefit plans, be recognized as an asset or liability in the
employers balance sheet. As required under the accounting rules which
44
existed prior to adoption of the new standard, we recognized an increase to stockholders equity of
$389.8 million at year-end 2006 primarily as a result of the improved funded position of the U.S.
defined benefit pension plan. Simultaneously, the adoption of FAS 158 resulted in a reduction to
stockholders equity of $342.6 million, which is included as a component of accumulated other
comprehensive income. The net effect of both of these adjustments was an increase in stockholders
equity of $47.2 million. These charges and adjustments did not affect our results of operations
and do not have a cash impact. In addition, they do not affect compliance with debt covenants in
our bank credit agreement.
We were not required to make cash contributions to our U.S. defined benefit pension plan for
2006, 2005 or 2004. During the fourth quarter 2006 and 2005, and the third quarter 2004, we made
voluntary contributions to this defined benefit pension plan of $100 million, $100 million and $50
million, respectively, to improve the plans funded position. Based on current regulations and
actuarial studies, we do not expect to be required to make cash contributions to our U.S. qualified
defined benefit pension plan for at least the next several years. We may elect, depending upon
investment performance of the pension plan assets and other factors, to make additional voluntary
cash contributions to this pension plan in the future.
We fund certain retiree health care benefits for Allegheny Ludlum using investments held in a
Company-administered Voluntary Employee Benefit Association (VEBA) trust. This allows us to recover
a portion of the retiree medical costs. In accordance with our labor agreements, during 2006, 2005,
and 2004, we funded $28.3 million, $24.7 million, and $18.2 million, respectively, of retiree
medical costs using the investments of the VEBA trust. We may continue to fund certain retiree
medical benefits utilizing the investments held in the VEBA. The value of the investments held in
the VEBA was approximately $93 million as of November 30, 2006, our measurement date for accounting
purposes.
Dividends
We paid a quarterly dividend of $0.10 per share of common stock for each of the first three
quarters of 2006. In the fourth quarter of 2006, our Board of Directors increased the cash dividend
paid on our common stock to $0.13 per share. During 2004 and the first three quarters of 2005, we
paid a quarterly dividend of $0.06 per share of common stock. In the fourth quarter of 2005, our
Board of Directors increased the cash dividend paid on our common stock to $0.10 per share. The
payment of dividends and the amount of such dividends depends upon matters deemed relevant by our
Board of Directors, such as our results of operations, financial condition, cash requirements,
future prospects, any limitations imposed by credit agreements or senior securities, and other
factors deemed relevant and appropriate.
Critical Accounting Policies
The accompanying consolidated financial statements have been prepared in conformity with United
States generally accepted accounting principles. When more than one accounting principle, or the
method of its application, is generally accepted, management selects the principle or method that
is appropriate in our specific circumstances. Application of these accounting principles requires
our management to make estimates about the future resolution of existing uncertainties; as a
result, actual results could differ from these estimates. In preparing these financial statements,
management has made its best estimates and judgments of the amounts and disclosures included in the
financial statements giving due regard to materiality.
Revenue Recognition and Accounts Receivable
Revenue is recognized when title passes or as services are rendered. We have no significant unusual
sale arrangements with any of our customers.
We market our products to a diverse customer base, principally throughout the United States.
Trade credit is extended based upon evaluations of each customers ability to perform its
obligations, which are updated periodically. Accounts receivable reserves are based upon an aging
of accounts and a review for collectibility of specific accounts. Accounts receivable are presented
net of a reserve for doubtful accounts of $5.7 million at December 31, 2006 and $8.1 million at
December 31, 2005, which represented 0.9% and 1.8%, respectively, of total gross accounts
receivable. During 2006, we wrote off $1.7 million of uncollectible accounts, which reduced the
reserve, and also reduced expense by $0.7 million from decreasing the reserve for doubtful
accounts. During 2005, we recognized expense of $1.7 million to increase the reserve for doubtful
accounts and wrote off $2.0 million of uncollectible accounts, which reduced the reserve.
45
Inventories
At December 31, 2006, we had net inventory of $798.7 million. Inventories are stated at the lower
of cost (last-in, first-out (LIFO), first-in, first-out (FIFO) and average cost methods) or market,
less progress payments. Costs include direct material, direct labor and applicable manufacturing
and engineering overhead, and other direct costs. Most of our inventory is valued utilizing the
LIFO costing methodology. Inventory of our non-U.S. operations is valued using average cost or FIFO
methods. Under the LIFO inventory valuation method, changes in the cost of raw materials and
production activities are recognized in cost of sales in the current period even though these
material and other costs may have been incurred at significantly different values due to the length
of time of our production cycle. The prices for many of the raw materials we use have been
extremely volatile during the past three years. Since we value most of our inventory utilizing the
LIFO inventory costing methodology, a rapid rise in raw material costs has a negative effect on our
operating results. For example, in 2006, 2005, and 2004, the effect of the increase in raw material
costs on our LIFO inventory valuation method resulted in cost of sales which was $197.0 million,
$45.8 million, and $112.2 million higher, respectively, than would have been recognized if we
utilized the FIFO methodology to value our inventory. In a period of rising prices, cost of sales
expense recognized under LIFO is generally higher than the cash costs incurred to acquire the
inventory sold. Conversely, in a period of declining raw material prices, cost of sales recognized
under LIFO is generally lower than cash costs incurred to acquire the inventory sold.
We evaluate product lines on a quarterly basis to identify inventory values that exceed
estimated net realizable value. The calculation of a resulting reserve, if any, is recognized as an
expense in the period that the need for the reserve is identified. At December 31, 2006, no such
reserves were required. It is our general policy to write-down to scrap value any inventory that is
identified as obsolete and any inventory that has aged or has not moved in more than twelve months.
In some instances this criterion is up to twenty-four months due to the longer manufacturing and
distribution process for such products.
Asset Impairment
We monitor the recoverability of the carrying value of our long-lived assets. An impairment charge
is recognized when the expected net undiscounted future cash flows from an assets use (including
any proceeds from disposition) are less than the assets carrying value, and the assets carrying
value exceeds its fair value. Changes in the expected use of a long-lived asset group, and the
financial performance of the long-lived asset group and its operating segment, are evaluated as
indicators of possible impairment. Future cash flow value may include appraisals for property,
plant and equipment, land and improvements, future cash flow estimates from operating the
long-lived assets, and other operating considerations.
At December 31, 2006, we had $206 million of goodwill on our balance sheet. Changes in the
goodwill balance from 2005 are due to foreign currency translation. Of the total, $112 million
related to the Flat-Rolled Products segment, $68 million related to the High Performance Metals
segment, and $26 million related to the Engineered Products segment. Goodwill is required to be
reviewed annually, or more frequently if impairment indicators arise. The impairment test for
goodwill is a two-step process. The first step is a comparison of the fair value of the reporting
unit with its carrying amount, including goodwill. If this comparison reflects impairment, then the
loss would be measured as the excess of recorded goodwill over its implied fair value. Implied fair
value is the excess of the fair value of the reporting unit over the fair value of all recognized
and unrecognized assets and liabilities.
We perform our annual evaluation of goodwill for possible impairment during the fourth
quarter. Our evaluation of goodwill for possible impairment includes estimating the fair market
value of each of the reporting units that have goodwill associated with their operations using
discounted cash flow and multiples of cash earnings valuation techniques, plus valuation
comparisons to recent public sale transactions of similar businesses, if any. These valuation
methods require us to make estimates and assumptions regarding future operating results, cash flows
including changes in working capital and capital expenditures, selling prices, profitability, and
the cost of capital. Although we believe that the estimates and assumptions used were reasonable,
actual results could differ from those estimates and assumptions. No goodwill impairment was
determined to exist for the years ended December 31, 2006, 2005 or 2004.
46
Contingencies
When it is probable that a liability has been incurred or an asset has been impaired, we recognize
a loss if the amount of the loss can be reasonably estimated.
We are subject to various domestic and international environmental laws and regulations that
govern the discharge of pollutants, and disposal of wastes, and which may require that we
investigate and remediate the effects of the release or disposal of materials at sites associated
with past and present operations. We could incur substantial cleanup costs, fines and civil or
criminal sanctions, third party property damage or personal injury claims as a result of violations
or liabilities under these laws or non-compliance with environmental permits required at our
facilities. We are currently involved in the investigation and remediation of a number of our
current and former sites as well as third party sites.
With respect to proceedings brought under the Federal Superfund laws, or similar state
statutes, we have been identified as a potentially responsible party (PRP) at approximately 28 of
such sites, excluding those at which we believe we have no future liability. Our involvement is
limited or de minimis at approximately 21 of these sites, and the potential loss exposure with
respect to any of the remaining 7 individual sites is not considered to be material.
We are a party to various cost-sharing arrangements with other PRPs at the sites. The terms of
the cost-sharing arrangements are subject to non-disclosure agreements as confidential information.
Nevertheless, the cost-sharing arrangements generally require all PRPs to post financial assurance
of the performance of the obligations or to pre-pay into an escrow or trust account their share of
anticipated site-related costs. In addition, the Federal government, through various agencies, is a
party to several such arrangements.
Environmental liabilities are recorded when our liability is probable and the costs are
reasonably estimable. In many cases, we are not able to determine whether we are liable or, if
liability is probable, to reasonably estimate the loss or range of loss. Estimates of our liability
are further subject to additional uncertainties including the nature and extent of site
contamination, available remediation alternatives, the extent of corrective actions that may be
required, and the participation, number and financial condition of other PRPs. We intend to adjust
our accruals to reflect new information as appropriate. Future adjustments could have a material
adverse effect on our results of operations in a given period, but we cannot reliably predict the
amounts of such future adjustments. At December 31, 2006, our reserves for environmental matters
totaled approximately $25 million.
Accruals for losses from environmental remediation obligations do not take into account the
effects of inflation, and anticipated expenditures are not discounted to their present value. The
accruals are not reduced by possible recoveries from insurance carriers or other third parties, but
do reflect allocations among PRPs at Federal Superfund sites or similar state-managed sites after
an assessment is made of the likelihood that such parties will fulfill their obligations at such
sites and after appropriate cost-sharing or other agreements are entered. Our measurement of
environmental liabilities is based on currently available facts, present laws and regulations, and
current technology. Such estimates take into consideration our prior experience in site
investigation and remediation, the data concerning cleanup costs available from other companies and
regulatory authorities, and the professional judgment of our environmental experts in consultation
with outside environmental specialists, when necessary.
Based on currently available information, we do not believe that there is a reasonable
possibility that a loss exceeding the amount already accrued for any of the matters with which we
are currently associated (either individually or in the aggregate) will be an amount that would be
material to a decision to buy or sell our securities. Future developments, administrative actions
or liabilities relating to environmental matters, however, could have a material adverse effect on
our financial condition or results of operations.
Retirement Benefits
We have defined benefit pension plans and defined contribution plans covering substantially all of
our employees. In the fourth quarter 2006 and 2005, and in third quarter 2004, we made voluntary
cash contributions of $100 million, $100 million and $50 million, respectively, to our U.S.
qualified defined benefit pension plan to improve the plans funded position. We are not required
to make a contribution to the U.S. qualified defined benefit pension plan for 2007, and, based upon
current regulations and actuarial analyses, we do not expect to be required to make cash
47
contributions to the U.S. qualified defined benefit pension plan for at least the next several
years. However, we may elect, depending upon the investment performance of the pension plan assets
and other factors, to make additional voluntary cash contributions to this pension plan in the
future.
We account for our defined benefit pension plans in accordance with Statement of Financial
Accounting Standards No. 87, Employers Accounting for Pensions (FAS 87), as amended by FAS 158
regarding the balance sheet presentation of pension assets and liabilities. FAS 87 requires that
amounts recognized in financial statements be determined on an actuarial basis, rather than as
contributions are made to the plan. A significant element in determining our pension (expense)
income in accordance with FAS 87 is the expected investment return on plan assets. In establishing
the expected return on plan investments, which is reviewed annually in the fourth quarter, we take
into consideration input from our third party pension plan asset managers and actuaries regarding
the types of securities the plan assets are invested in, how those investments have performed
historically, and expectations for how those investments will perform in the future. Our expected
return on pension plan investments is 8.75%. We apply this assumed rate to the market value of plan
assets at the end of the previous year. This produces the expected return on plan assets that is
included in annual pension (expense) income for the current year. The actual return on pension plan
assets was 18.2% for 2006, 9.7% for 2005, 11.7% for 2004, and 13.1% for 2003. While the actual
return on pension plan investments has exceeded the expected return on pension plan investments for
each of the past four years, our expected return on pension plan investments for 2007 remains at
8.75%. The effect of increasing, or lowering, the expected return on pension plan investments by
0.25% results in additional annual income, or expense, of approximately $5.4 million. The
cumulative difference between this expected return and the actual return on plan assets is deferred
and amortized into pension income or expense over future periods. The amount of expected return on
plan assets can vary significantly from year-to-year since the calculation is dependent on the
market value of plan assets as of the end of the preceding year. U.S. generally accepted accounting
principles allow companies to calculate the expected return on pension assets using either an
average of fair market values of pension assets over a period not to exceed five years, which
reduces the volatility in reported pension income or expense, or their fair market value at the end
of the previous year. However, the Securities and Exchange Commission currently does not permit
companies to change from the fair market value at the end of the previous year methodology, which
is the methodology that we use, to an averaging of fair market values of plan assets methodology.
As a result, our results of operations and those of other companies, including companies with which
we compete, may not be comparable due to these different methodologies in calculating the expected
return on pension investments.
At the end of November of each year, we determine the discount rate to be used to value
pension plan liabilities. In accordance with FAS 87, the discount rate reflects the current rate at
which the pension liabilities could be effectively settled. In estimating this rate, we receive
input from our actuaries regarding the rates of return on high quality, fixed-income investments
with maturities matched to the expected future retirement benefit payments. Based on this
assessment at the end of November 2006, we established a discount rate of 5.8% for valuing the
pension liabilities as of the end of 2006, and for determining the pension expense for 2007. We had
previously assumed a discount rate of 5.9% for 2005, which determined the 2006 expense, 6.1% for
2004, which determined the 2005 expense, and 6.5% for 2003, which determined the 2004 expense. The
effect of lowering the discount rate to 5.8%, from 5.9% in the previous year, increased pension
liabilities by approximately $22 million at 2006 year-end, and is expected to increase pension
expense by approximately $3.5 million in 2007. The effect on pension liabilities for changes to the
discount rate, as well as the net effect of other changes in actuarial assumptions and experience,
are deferred and amortized over future periods in accordance with FAS 87.
We adopted FAS 158 as of fiscal year-end 2006. FAS 158 requires that the net funded position
of the plans, as measured by the projected benefit obligation (PBO) in the case of pension plans,
and by the accumulated postretirement benefit obligation (APBO) in the case of other
postretirement benefit plans, be recognized as an asset or liability in the employers balance
sheet. Prior period information is not restated. In addition, the new standard will require
assets and benefits to be measured at the date of our statement of financial position, which is
December 31, rather than our measurement date of November 30, as currently permitted. This change
will be effective for our 2008 fiscal year.
Prior to the adoption of FAS 158, the funded status of pension plans was measured by the
accumulated benefit obligation (ABO). At the November 30, 2006, measurement date, our U.S.
qualified defined benefit pension plan was overfunded on an ABO basis, and we reversed the
previously-recorded minimum pension liability and
48
accumulated other comprehensive income (loss) associated with this plan when it had been in an
ABO underfunded position, recorded a prepaid pension cost asset of $569.9 million, and increased
stockholders equity by $389.8 million, net of related deferred tax effects. However, on a PBO
basis, which is the funded status measure required by FAS 158, our U.S. qualified defined benefit
pension plan was underfunded by $5.6 million at the measurement date. For our U.S. qualified
defined benefit pension plan, the adoption of FAS 158 eliminated the $569.9 million prepaid pension
cost, established a $5.6 million noncurrent liability, and reduced stockholders equity by $345.3
million, net of related deferred tax effects. We also sponsor other non-qualified defined benefit
pension plans in the U.S., a defined benefit pension plan in the U.K., and several postretirement
benefit plans. Including these other pension and postretirement benefit plans, the aggregate
effect of adopting FAS 158 reduced stockholders equity by $342.6 million, net of related deferred
tax effects, as a component of accumulated other comprehensive income (loss). The net effect of
these adjustments was an increase in stockholders equity of $47.2 million. These charges and
adjustments did not affect our results of operations and do not have a cash impact. In addition,
they do not affect compliance with debt covenants in our bank credit agreement.
We also sponsor several postretirement plans covering certain hourly and salaried employees
and retirees. These plans provide health care and life insurance benefits for eligible employees.
Under most of the plans, our contributions towards premiums are capped based upon the cost as of a
certain date, thereby creating a defined contribution. For the non-collectively bargained plans, we
maintain the right to amend or terminate the plans in the future. We account for these benefits in
accordance with SFAS No. 106, Employers Accounting for Postretirement Benefits Other Than
Pensions (FAS 106), as amended by FAS 158 regarding the balance sheet display of pension and
other postretirement benefits obligations assets and liabilities, which requires that amounts
recognized in financial statements be determined on an actuarial basis, rather than as benefits are
paid. We use actuarial assumptions, including the discount rate and the expected trend in health
care costs, to estimate the costs and benefit obligations for the plans. The discount rate, which
is determined annually at the end of November of each year, is developed based upon rates of return
on high quality, fixed-income investments. At the end of 2006, we determined this rate to be 5.8%,
a reduction from a 5.9% discount rate in 2005, 6.1% discount rate in 2004 and 6.50% in 2003. The
effect of lowering the discount rate to 5.8% from 5.9% increased 2006 postretirement benefit
liabilities by approximately $3 million, compared to the prior year, and 2007 expenses are expected
to increase by approximately $0.5 million. Based upon predictions of continued significant medical
cost inflation in future years, the annual assumed rate of increase in the per capita cost of
covered benefits for health care plans is 10.0% for 2007 and is assumed to gradually decrease to
5.0% in the year 2016 and remain level thereafter.
The Medicare Prescription Drug, Improvement and Modernization Act provides for a federal
subsidy, with tax-free payments commencing in 2006, to sponsors of retiree health care benefits
plans that provide a benefit that is at least actuarially equivalent to the benefit established by
the law. The federal subsidy included in the law resulted in a reduction of our other
postretirement benefits obligation of approximately $70 million,
which will be recognized in operating results over a number of years as an actuarial experience gain. As a result of this
reduction of our other postretirement benefits obligation, our 2006 and 2005 postretirement benefit
expense was reduced by approximately $10 million in each year.
Certain of these postretirement benefits are funded using plan investments held in a
Company-administered VEBA trust. The expected return on plan investments is a significant element
in determining postretirement benefits expenses in accordance with FAS 106. In establishing the
expected return on plan investments, which is reviewed annually in the fourth quarter, we take into
consideration the types of securities the plan assets are invested in, how those investments have
performed historically, and expectations for how those investments will perform in the future. For
2006, our expected return on investments held in the VEBA trust was 9%. This assumed long-term rate
of return on investments is applied to the market value of plan assets at the end of the previous
year. This produces the expected return on plan investments that is included in annual
postretirement benefits expenses for the current year. While the actual return on investments held
in the VEBA trust was 50.0% in 2006, 11.6% in both 2005 and 2004, and 9.3% for 2003, our expected
return on investments in the VEBA trust remains 9% for 2007. The expected return on investments
held in the VEBA trust is expected to exceed the return on pension plan investments due to a higher
percentage of private equity investments held by the VEBA trust.
49
New Accounting Pronouncements
In September 2006, the Financial Accounting Standards Board issued FAS 158, an amendment to its
standards for defined benefit pension and other postretirement benefit plans accounting. The new
standard requires that the net funded position of the plans, as measured by the projected benefit
obligation in the case of pension plans, and by the accumulated postretirement benefit obligation
in the case of other postretirement benefit plans, be recognized as an asset or liability in the
employers balance sheet. As required under the accounting rules which existed prior to adoption
of the new standard, we recognized an increase to stockholders equity of $389.8 million at
year-end 2006 primarily as a result of the improved funded position of our U.S. qualified defined
benefit pension plan. Simultaneously, the adoption of FAS 158 resulted in a reduction to
stockholders equity of $342.6 million, which is included as a component of accumulated other
comprehensive income. The net effect of both of these adjustments was an increase in stockholders
equity of $47.2 million. In addition, the new standard will require assets and benefits to be
measured at the date of the employers statement of financial position, which is December 31 in our
case, rather than our measurement date of November 30, as currently permitted. This change will be
effective for ATIs 2008 fiscal year.
The FASB issued, in September 2006, a FASB Staff Position (FSP) titled Accounting for
Planned Major Maintenance Activities (FSP PMMA). This FSP amends an AICPA Industry Audit guide
and is applicable to all industries that accrue for planned major maintenance activities. The FSP
PMMA prohibits the use of the accrue-in-advance method of accounting for planned major maintenance
activities, which is the policy we used to record planned plant outage costs on an interim basis
within a fiscal year, and also to record the costs of major equipment rebuilds which extend the
life of capital equipment. The FSP PMMA is effective as of the beginning of our 2007 fiscal year,
with retrospective application to all prior periods presented. Under the FSP PMMA, we will report
results using the deferral method whereby major equipment rebuilds are capitalized as costs are
incurred and amortized into expense over their estimated useful lives, and planned plant outage
costs are fully recognized in the interim period of the outage. The adoption of the FSP PMMA on
January 1, 2007, resulted in an increase to retained earnings of $12.2 million, net of related
taxes. Retrospectively applied, our net income for 2006, 2005 and 2004 increased $2.1 million,
$2.5 million and $1.6 million, respectively, or approximately $0.02 per share for each year.
Beginning with the 2007 first quarter, ATIs financial statements will reflect this FSP for all
periods, as if it had been applied to the earliest period presented.
In June 2006, the Financial Accounting Standards Board issued FASB Interpretation No. 48,
Accounting for Uncertainty in Income Taxes (FIN 48), an interpretation of FASB Statement No.
109, Accounting for Income Taxes. FIN 48 prescribes recognition and measurement standards for a
tax position taken or expected to be taken in a tax return. The evaluation of a tax position in
accordance with FIN 48 is a two step process. The first step is the determination of whether a tax
position should be recognized in the financial statements. Under FIN 48, a tax position taken or
expected to be taken in a tax return is to be recognized only if we determine that it is
more-likely-than-not that the tax position will be sustained upon examination by the tax
authorities based upon the technical merits of the position. In step two for those tax positions
which should be recognized, the measurement of a tax position is determined as being the largest
amount of benefit that is greater than 50% likely of being realized upon ultimate settlement. FIN
48 was effective for the beginning of ATIs 2007 fiscal year, with adoption treated as a
cumulative-effect type reduction to retained earnings in the range of $10 million as of the
beginning of 2007.
In the fourth quarter 2005, we adopted the Financial Accounting Standards Board (FASB)
Interpretation No. 47, Accounting for Conditional Asset Retirement Obligations (FIN 47), an
interpretation of FASB Statement No. 143, Accounting for Asset Retirement Obligations (SFAS
143). FIN 47 clarifies that the term conditional asset retirement obligation as used in SFAS 143
refers to a legal obligation to perform an asset retirement activity in which the timing and (or)
method of settlement are conditional on a future event that may or may not be within the control of
the entity. An entity is required to recognize a liability for the fair value of a conditional
asset retirement obligation if the fair value of the liability can be reasonably estimated, even if
conditional on a future event. For existing asset retirement obligations which are determined to be
recognizable under FIN 47, the effect of applying FIN 47 is recognized as a cumulative effect of a
change in accounting principle. Our adoption of FIN 47 resulted in recognizing a charge of $2.0
million, net of income taxes, or $0.02 per share, in the fourth quarter 2005 principally for
estimable asset retirement obligations related to remediation costs which would be incurred if we
were to cease certain manufacturing activities which utilize what may be categorized as potentially
hazardous materials.
50
In the first quarter 2005, we adopted FASB Statement No. 123(R), Share-Based Payment (SFAS
123R). Under this revised standard, companies may no longer account for share-based compensation
transactions, such as stock options, restricted stock, and potential payments under programs such
as our Total Shareholder Return Program (TSRP) awards, using the intrinsic value method as
defined in APB Opinion No. 25. Instead, companies are required to account for such equity
transactions using an approach in which the fair value of an award is estimated at the date of
grant and recognized as an expense over the requisite service period. Compensation expense is
adjusted for equity awards that do not vest because service or performance conditions are not
satisfied. However, compensation expense already recognized is not adjusted if market conditions
are not met, such as our total shareholder return performance relative to a peer group under our
TSRP awards, or for stock options expiring out-of-the-money. We adopted the new standard using
the modified prospective method, in which the effect of the standard is recognized in the period of
adoption and in future periods. Prior periods are not restated to reflect the impact of adopting
the new standard at earlier dates.
Forward-Looking Statements
From time-to-time, the Company has made and may continue to make forward-looking statements
within the meaning of the Private Securities Litigation Reform Act of 1995. Certain statements in
this report relate to future events and expectations and, as such, constitute forward-looking
statements. Forward-looking statements include those containing such words as anticipates,
believes, estimates, expects, would, should, will, will likely result, forecast,
outlook, projects, and similar expressions. Such forward-looking statements are based on
managements current expectations and include known and unknown risks, uncertainties and other
factors, many of which the Company is unable to predict or control, that may cause our actual
results or performance to materially differ from any future results or performance expressed or
implied by such statements. Various of these factors are described in Item 1A, Risk Factors, of
this Annual Report on Form 10-K and will be described from time-to-time in the Company filings with
the Securities and Exchange Commission (SEC), including the Companys Annual Reports on Form 10-K
and the Companys subsequent reports filed with the SEC on Form
10-Q and
Form 8-K, which are
available on the SECs website at http://www.sec.gov and on the Companys website at
http://www.alleghenytechnologies.com. We assume no duty to update our forward-looking statements.
51
Item 7A. Quantitative and Qualitative Disclosures About Market Risk
Interest Rate Risk.
We attempt to maintain a reasonable balance between fixed- and floating-rate
debt to keep financing costs as low as possible. At December 31, 2006, we had approximately $78
million of floating rate debt outstanding with a weighted average interest rate of approximately
6.1%. Approximately $54 million of this floating rate debt is capped at a 6% maximum interest rate,
and at December 31, 2006, was bearing interest at the capped 6% rate. Since the interest rate on
floating rate debt changes with the short-term market rate of interest, we are exposed to the risk
that these interest rates may increase, raising our interest expense in situations where the
interest rate is not capped. For example, a hypothetical 1% in rate of interest on the $24 million
of our outstanding floating rate debt not subjected to a cap would result in increased annual
financing costs of $0.2 million.
Volatility of Energy Prices.
Energy resources markets are subject to conditions that create
uncertainty in the prices and availability of energy resources. The prices for and availability of
electricity, natural gas, oil and other energy resources are subject to volatile market conditions.
These market conditions often are affected by political and economic factors beyond our control.
Increases in energy costs, or changes in costs relative to energy costs paid by competitors, have
and may continue to adversely affect our profitability. To the extent that these uncertainties
cause suppliers and customers to be more cost sensitive, increased energy prices may have an
adverse effect on our results of operations and financial condition. We use approximately 10 to 12
million MMBtus of natural gas annually, depending upon business conditions, in the manufacture of
our products. These purchases of natural gas expose us to risk of higher gas prices. For example, a
hypothetical $1.00 per MMBtu increase in the price of natural gas would result in increased annual
energy costs of approximately $10 to $12 million. We use several approaches to minimize any
material adverse effect on our financial condition or results of operations from volatile energy
prices. These approaches include incorporating an energy surcharge on many of our products and
using financial derivatives to reduce exposure to energy price volatility.
Volatility of Raw Material Prices.
We use raw materials surcharge and index mechanisms to offset
the impact of increased raw material costs; however, competitive factors in the marketplace can
limit our ability to institute such mechanisms, and there can be a delay between the increase in
the price of raw materials and the realization of the benefit of such mechanisms. For example,
since we generally use in excess of 85 million pounds of nickel each year, a hypothetical change of
$1.00 per pound in nickel prices would result in increased costs of approximately $85 million. In
addition, we also use in excess of 800 million pounds of ferrous scrap in the production of our
products and a hypothetical change of $0.01 per pound would result in increased costs of
approximately $8 million. While we enter into raw materials futures contracts from time-to-time to
hedge exposure to price fluctuations, such as for nickel, we cannot be certain that our hedge
position adequately reduces exposure. We believe that we have adequate controls to monitor these
contracts, but we may not be able to accurately assess exposure to price volatility in the markets
for critical raw materials.
52
Item 8. Financial Statements and Supplementary Data
Allegheny Technologies Incorporated and Subsidiaries
Consolidated Statements of Income
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(In millions except per share amounts)
|
|
|
|
|
|
|
|
|
|
|
For the Years Ended December 31,
|
|
2006
|
|
|
2005
|
|
|
2004
|
|
|
|
|
Sales
|
|
$
|
4,936.6
|
|
|
$
|
3,539.9
|
|
|
$
|
2,733.0
|
|
|
|
|
Costs and expenses:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Cost of sales
|
|
|
3,743.8
|
|
|
|
2,889.7
|
|
|
|
2,488.1
|
|
|
Selling and administrative expenses
|
|
|
295.3
|
|
|
|
275.8
|
|
|
|
233.3
|
|
|
Restructuring costs and curtailment (gain), net
|
|
|
|
|
|
|
23.9
|
|
|
|
(40.4
|
)
|
|
|
|
Income before interest, other income (expense), income taxes and
cumulative effect of change in accounting principle
|
|
|
897.5
|
|
|
|
350.5
|
|
|
|
52.0
|
|
|
Interest expense, net
|
|
|
(23.3
|
)
|
|
|
(38.6
|
)
|
|
|
(35.5
|
)
|
|
Other income (expense), net
|
|
|
(5.0
|
)
|
|
|
(4.8
|
)
|
|
|
3.3
|
|
|
|
|
Income before income taxes and cumulative effect of change in
accounting principle
|
|
|
869.2
|
|
|
|
307.1
|
|
|
|
19.8
|
|
|
Income tax provision (benefit)
|
|
|
297.3
|
|
|
|
(54.7
|
)
|
|
|
|
|
|
|
|
Income before cumulative effect of change in accounting principle
|
|
|
571.9
|
|
|
|
361.8
|
|
|
|
19.8
|
|
|
Cumulative effect of change in accounting principle, net of tax
|
|
|
|
|
|
|
(2.0
|
)
|
|
|
|
|
|
|
|
Net income
|
|
$
|
571.9
|
|
|
$
|
359.8
|
|
|
$
|
19.8
|
|
|
|
|
Basic income per common share before cumulative effect of change
in accounting principle
|
|
$
|
5.74
|
|
|
$
|
3.76
|
|
|
$
|
0.23
|
|
|
Cumulative effect of change in accounting principle
|
|
|
|
|
|
|
(0.02
|
)
|
|
|
|
|
|
|
|
Basic net income per common share
|
|
$
|
5.74
|
|
|
$
|
3.74
|
|
|
$
|
0.23
|
|
|
|
|
Diluted income per common share before cumulative effect of
change in accounting principle
|
|
$
|
5.59
|
|
|
$
|
3.59
|
|
|
$
|
0.22
|
|
|
Cumulative effect of change in accounting principle
|
|
|
|
|
|
|
(0.02
|
)
|
|
|
|
|
|
|
|
Diluted net income per common share
|
|
$
|
5.59
|
|
|
$
|
3.57
|
|
|
$
|
0.22
|
|
|
|
The accompanying notes are an integral part of these statements.
53
Allegheny Technologies Incorporated and Subsidiaries
Consolidated Balance Sheets
|
|
|
|
|
|
|
|
|
|
|
|
|
December 31,
|
|
|
December 31,
|
|
|
(In millions except share and per share amounts)
|
|
2006
|
|
|
2005
|
|
|
|
|
Assets
|
|
|
|
|
|
|
|
|
|
Cash and cash equivalents
|
|
$
|
502.3
|
|
|
$
|
362.7
|
|
|
Accounts receivable, net
|
|
|
610.9
|
|
|
|
442.1
|
|
|
Inventories, net
|
|
|
798.7
|
|
|
|
607.1
|
|
|
Deferred income taxes
|
|
|
26.6
|
|
|
|
22.8
|
|
|
Prepaid expenses and other current assets
|
|
|
49.4
|
|
|
|
49.3
|
|
|
|
|
Total Current Assets
|
|
|
1,987.9
|
|
|
|
1,484.0
|
|
|
Property, plant and equipment, net
|
|
|
867.6
|
|
|
|
704.9
|
|
|
Cost in excess of net assets acquired
|
|
|
206.5
|
|
|
|
199.7
|
|
|
Deferred income taxes
|
|
|
124.8
|
|
|
|
155.3
|
|
|
Deferred pension asset
|
|
|
|
|
|
|
100.6
|
|
|
Other assets
|
|
|
95.4
|
|
|
|
87.1
|
|
|
|
|
Total Assets
|
|
$
|
3,282.2
|
|
|
$
|
2,731.6
|
|
|
|
|
Liabilities and Stockholders Equity
|
|
|
|
|
|
|
|
|
|
Accounts payable
|
|
$
|
355.1
|
|
|
$
|
312.9
|
|
|
Accrued liabilities
|
|
|
266.7
|
|
|
|
234.6
|
|
|
Short-term debt and current portion of long-term debt
|
|
|
23.7
|
|
|
|
13.4
|
|
|
|
|
Total Current Liabilities
|
|
|
645.5
|
|
|
|
560.9
|
|
|
Long-term debt
|
|
|
529.9
|
|
|
|
547.0
|
|
|
Accrued postretirement benefits
|
|
|
428.6
|
|
|
|
461.5
|
|
|
Pension liabilities
|
|
|
35.8
|
|
|
|
242.9
|
|
|
Other long-term liabilities
|
|
|
149.8
|
|
|
|
119.4
|
|
|
|
|
Total Liabilities
|
|
|
1,789.6
|
|
|
|
1,931.7
|
|
|
|
|
Stockholders Equity:
|
|
|
|
|
|
|
|
|
|
Preferred stock, par value $0.10: authorized - 50,000,000 shares; issued none
|
|
|
|
|
|
|
|
|
|
Common stock, par value $0.10: authorized - 500,000,000 shares; issued
101,201,411 at 2006 and 98,951,490 at 2005; outstanding 101,201,328 shares
at 2006 and 98,200,561 shares at 2005
|
|
|
10.1
|
|
|
|
9.9
|
|
|
Additional paid-in capital
|
|
|
637.0
|
|
|
|
535.6
|
|
|
Retained earnings
|
|
|
1,156.3
|
|
|
|
642.6
|
|
|
Treasury stock: 83 shares at 2006 and 750,929 shares at 2005
|
|
|
|
|
|
|
(18.8
|
)
|
|
Accumulated other comprehensive loss, net of tax
|
|
|
(310.8
|
)
|
|
|
(369.4
|
)
|
|
|
|
Total Stockholders Equity
|
|
|
1,492.6
|
|
|
|
799.9
|
|
|
|
|
Total Liabilities and Stockholders Equity
|
|
$
|
3,282.2
|
|
|
$
|
2,731.6
|
|
|
|
The accompanying notes are an integral part of these statements.
54
Allegheny Technologies Incorporated and Subsidiaries
Consolidated Statements of Cash Flows
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(In millions)
|
|
|
|
|
|
|
|
|
|
|
For the Years Ended December 31,
|
|
2006
|
|
|
2005
|
|
|
2004
|
|
|
|
|
Operating Activities:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net income
|
|
$
|
571.9
|
|
|
$
|
359.8
|
|
|
$
|
19.8
|
|
|
Adjustments to reconcile net income to net cash provided by operating
activities:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Cumulative effect of change in accounting principle
|
|
|
|
|
|
|
2.0
|
|
|
|
|
|
|
Depreciation and amortization
|
|
|
84.2
|
|
|
|
77.3
|
|
|
|
76.1
|
|
|
Non-cash restructuring costs and curtailment (gain), net
|
|
|
|
|
|
|
22.4
|
|
|
|
(45.6
|
)
|
|
Deferred income taxes
|
|
|
8.2
|
|
|
|
(92.0
|
)
|
|
|
(0.4
|
)
|
|
Change in operating assets and liabilities:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Inventories
|
|
|
(191.6
|
)
|
|
|
(87.9
|
)
|
|
|
(96.8
|
)
|
|
Accounts receivable
|
|
|
(168.8
|
)
|
|
|
(78.7
|
)
|
|
|
(78.4
|
)
|
|
Pension assets and liabilities (a)
|
|
|
(43.3
|
)
|
|
|
(42.3
|
)
|
|
|
18.2
|
|
|
Accounts payable
|
|
|
42.2
|
|
|
|
39.0
|
|
|
|
83.7
|
|
|
Accrued liabilities
|
|
|
30.7
|
|
|
|
38.7
|
|
|
|
11.0
|
|
|
Postretirement benefits
|
|
|
(6.3
|
)
|
|
|
(11.1
|
)
|
|
|
18.9
|
|
|
Accrued income taxes, net of tax benefit on share-based compensation
|
|
|
4.2
|
|
|
|
18.5
|
|
|
|
7.2
|
|
|
Other
|
|
|
(22.9
|
)
|
|
|
(23.1
|
)
|
|
|
10.4
|
|
|
|
|
Cash provided by operating activities
|
|
|
308.5
|
|
|
|
222.6
|
|
|
|
24.1
|
|
|
|
|
Investing Activities:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Purchases of property, plant and equipment
|
|
|
(235.2
|
)
|
|
|
(90.1
|
)
|
|
|
(49.9
|
)
|
|
Purchase of businesses and investments in ventures, net of cash acquired
|
|
|
|
|
|
|
(18.3
|
)
|
|
|
(7.5
|
)
|
|
Disposals of property, plant and equipment
|
|
|
2.0
|
|
|
|
0.6
|
|
|
|
6.6
|
|
|
Proceeds from sales of businesses and investments and other
|
|
|
0.5
|
|
|
|
(1.4
|
)
|
|
|
(3.8
|
)
|
|
|
|
Cash used in investing activities
|
|
|
(232.7
|
)
|
|
|
(109.2
|
)
|
|
|
(54.6
|
)
|
|
|
|
Financing Activities:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Payments of long-term debt and capital leases
|
|
|
(7.8
|
)
|
|
|
(38.5
|
)
|
|
|
(27.1
|
)
|
|
Borrowings of long-term debt
|
|
|
|
|
|
|
11.0
|
|
|
|
11.7
|
|
|
Net borrowings (repayments) under credit facilities
|
|
|
0.7
|
|
|
|
1.8
|
|
|
|
(0.5
|
)
|
|
|
|
Net repayments
|
|
|
(7.1
|
)
|
|
|
(25.7
|
)
|
|
|
(15.9
|
)
|
|
Dividends paid
|
|
|
(43.1
|
)
|
|
|
(27.1
|
)
|
|
|
(21.2
|
)
|
|
Exercises of stock options
|
|
|
33.1
|
|
|
|
26.1
|
|
|
|
7.6
|
|
|
Tax benefit on share-based compensation
|
|
|
80.9
|
|
|
|
25.2
|
|
|
|
|
|
|
Issuance of common stock
|
|
|
|
|
|
|
|
|
|
|
229.7
|
|
|
Proceeds from interest rate swap settlement
|
|
|
|
|
|
|
|
|
|
|
1.5
|
|
|
|
|
Cash provided by (used in) financing activities
|
|
|
63.8
|
|
|
|
(1.5
|
)
|
|
|
201.7
|
|
|
|
|
Increase in cash and cash equivalents
|
|
|
139.6
|
|
|
|
111.9
|
|
|
|
171.2
|
|
|
Cash and cash equivalents at beginning of year
|
|
|
362.7
|
|
|
|
250.8
|
|
|
|
79.6
|
|
|
|
|
Cash and cash equivalents at end of year
|
|
$
|
502.3
|
|
|
$
|
362.7
|
|
|
$
|
250.8
|
|
|
|
|
|
|
|
|
(a)
|
|
Includes annual voluntary cash pension contributions of $(100.0) million in 2006 and 2005, and
$(50.0) million in 2004.
|
Amounts presented on the Consolidated Statements of Cash Flows may not agree to the corresponding
changes in balance sheet items due to the accounting for purchases and sales of businesses and the
effects of foreign currency translation.
The accompanying notes are an integral part of these statements.
55
Allegheny Technologies Incorporated and Subsidiaries
Consolidated Statements of Stockholders Equity
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Accumulated
|
|
|
|
|
|
|
|
|
|
|
|
Additional
|
|
|
|
|
|
|
|
|
|
|
Other
|
|
|
Stock-
|
|
|
|
|
Common
|
|
|
Paid-In
|
|
|
Retained
|
|
|
Treasury
|
|
|
Comprehensive
|
|
|
holders
|
|
|
(In millions except per share amounts)
|
|
Stock
|
|
|
Capital
|
|
|
Earnings
|
|
|
Stock
|
|
|
Income (Loss)
|
|
|
Equity
|
|
|
|
|
Balance, December 31, 2003
|
|
$
|
9.9
|
|
|
$
|
481.2
|
|
|
$
|
483.8
|
|
|
$
|
(458.4
|
)
|
|
$
|
(341.8
|
)
|
|
$
|
174.7
|
|
|
|
|
Net income
|
|
|
|
|
|
|
|
|
|
|
19.8
|
|
|
|
|
|
|
|
|
|
|
|
19.8
|
|
|
Other comprehensive income (loss),
net of tax:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Minimum pension liability
adjustment
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
2.1
|
|
|
|
2.1
|
|
|
Foreign currency translation gains
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
20.8
|
|
|
|
20.8
|
|
|
Unrealized losses on derivatives
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(12.4
|
)
|
|
|
(12.4
|
)
|
|
|
|
Comprehensive income
|
|
|
|
|
|
|
|
|
|
|
19.8
|
|
|
|
|
|
|
|
10.5
|
|
|
|
30.3
|
|
|
Cash dividends on common stock ($0.24
per share)
|
|
|
|
|
|
|
|
|
|
|
(21.2
|
)
|
|
|
|
|
|
|
|
|
|
|
(21.2
|
)
|
|
Issuance of common stock
|
|
|
|
|
|
|
|
|
|
|
(116.0
|
)
|
|
|
345.7
|
|
|
|
|
|
|
|
229.7
|
|
|
Employee stock plans
|
|
|
|
|
|
|
|
|
|
|
(20.9
|
)
|
|
|
33.3
|
|
|
|
|
|
|
|
12.4
|
|
|
|
|
Balance, December 31, 2004
|
|
|
9.9
|
|
|
|
481.2
|
|
|
|
345.5
|
|
|
|
(79.4
|
)
|
|
|
(331.3
|
)
|
|
|
425.9
|
|
|
|
|
Net income
|
|
|
|
|
|
|
|
|
|
|
359.8
|
|
|
|
|
|
|
|
|
|
|
|
359.8
|
|
|
Other comprehensive income (loss),
net of tax:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Minimum pension liability
adjustment
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(36.0
|
)
|
|
|
(36.0
|
)
|
|
Foreign currency translation losses
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(22.7
|
)
|
|
|
(22.7
|
)
|
|
Unrealized gains on derivatives
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
20.5
|
|
|
|
20.5
|
|
|
Change in unrealized gains on
securities
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
0.1
|
|
|
|
0.1
|
|
|
|
|
Comprehensive income
|
|
|
|
|
|
|
|
|
|
|
359.8
|
|
|
|
|
|
|
|
(38.1
|
)
|
|
|
321.7
|
|
|
Cash dividends on common stock ($0.28
per share)
|
|
|
|
|
|
|
|
|
|
|
(27.1
|
)
|
|
|
|
|
|
|
|
|
|
|
(27.1
|
)
|
|
Employee stock plans
|
|
|
|
|
|
|
54.4
|
|
|
|
(35.6
|
)
|
|
|
60.6
|
|
|
|
|
|
|
|
79.4
|
|
|
|
|
Balance, December 31, 2005
|
|
|
9.9
|
|
|
|
535.6
|
|
|
|
642.6
|
|
|
|
(18.8
|
)
|
|
|
(369.4
|
)
|
|
|
799.9
|
|
|
|
|
Net income
|
|
|
|
|
|
|
|
|
|
|
571.9
|
|
|
|
|
|
|
|
|
|
|
|
571.9
|
|
|
Other comprehensive income (loss),
net of tax:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Minimum pension liability
adjustment
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
389.8
|
|
|
|
389.8
|
|
|
Foreign currency translation gains
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
24.3
|
|
|
|
24.3
|
|
|
Unrealized losses on derivatives
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(13.6
|
)
|
|
|
(13.6
|
)
|
|
Change in unrealized gains on
securities
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
0.7
|
|
|
|
0.7
|
|
|
|
|
Comprehensive income
|
|
|
|
|
|
|
|
|
|
|
571.9
|
|
|
|
|
|
|
|
401.2
|
|
|
|
973.1
|
|
|
Adjustment to initially apply FASB
Statement No. 158, net of tax
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(342.6
|
)
|
|
|
(342.6
|
)
|
|
Cash dividends on common stock ($0.43
per share)
|
|
|
|
|
|
|
|
|
|
|
(43.1
|
)
|
|
|
|
|
|
|
|
|
|
|
(43.1
|
)
|
|
Employee stock plans
|
|
|
0.2
|
|
|
|
101.4
|
|
|
|
(15.1
|
)
|
|
|
18.8
|
|
|
|
|
|
|
|
105.3
|
|
|
|
|
Balance, December 31, 2006
|
|
$
|
10.1
|
|
|
$
|
637.0
|
|
|
$
|
1,156.3
|
|
|
$
|
|
|
|
$
|
(310.8
|
)
|
|
$
|
1,492.6
|
|
|
|
The accompanying notes are an integral part of these statements.
56
Report of Independent Registered Public Accounting Firm
Board of Directors
Allegheny Technologies Incorporated
We have audited the accompanying consolidated balance sheets of Allegheny Technologies Incorporated
and subsidiaries as of December 31, 2006 and 2005, and the related consolidated statements of
income, stockholders equity, and cash flows for each of the three years in the period ended
December 31, 2006. These financial statements are the responsibility of the Companys management.
Our responsibility is to express an opinion on these financial statements based on our audits.
We conducted our audits in accordance with the standards of the Public Company Accounting
Oversight Board (United States). Those standards require that we plan and perform the audit to
obtain reasonable assurance about whether the financial statements are free of material
misstatement. An audit includes examining, on a test basis, evidence supporting the amounts and
disclosures in the financial statements. An audit also includes assessing the accounting principles
used and significant estimates made by management, as well as evaluating the overall financial
statement presentation. We believe that our audits provide a reasonable basis for our opinion.
In our opinion, the financial statements referred to above present fairly, in all material
respects, the consolidated financial position of Allegheny Technologies Incorporated and
subsidiaries at December 31, 2006 and 2005, and the consolidated results of their operations and
their cash flows for each of the three years in the period ended December 31, 2006, in conformity
with U.S. generally accepted accounting principles.
As described in Note 9 to the financial statements, in 2006 the Company changed its method of
accounting for pensions and other postretirement benefits. As described in Note 1 to the financial
statements, in 2005 the Company changed its methods of accounting for stock-based compensation and
conditional asset retirement obligations.
We also have audited, in accordance with the standards of the Public Company Accounting
Oversight Board (United States), the effectiveness of Allegheny Technologies Incorporateds
internal control over financial reporting as of December 31, 2006, based on criteria established in
Internal ControlIntegrated Framework issued by the Committee of Sponsoring Organizations of the
Treadway Commission and our report dated February 21, 2007 expressed an unqualified opinion
thereon.
/s/ Ernst & Young LLP
Pittsburgh, Pennsylvania
February 21, 2007
57
Notes to Consolidated Financial Statements
Note 1. Summary of Significant Accounting Policies
Principles of Consolidation
The consolidated financial statements include the accounts of Allegheny Technologies Incorporated
and its subsidiaries, including the Chinese joint venture known as Shanghai STAL Precision
Stainless Steel Company Limited (STAL), in which the Company has a 60% interest. The remaining
40% interest in STAL is owned by Baosteel Group, a state authorized investment company whose equity
securities are publicly traded in the Peoples Republic of China. The financial results of STAL are
consolidated into the Companys operating results with the 40% interest of the Companys minority
partner recognized on the statement