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, 2007
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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
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25-1792394
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(State or other jurisdiction of incorporation
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(I.R.S. Employer
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or organization)
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Identification Number)
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1000 Six PPG Place, Pittsburgh, Pennsylvania
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15222-5479
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(Address of principal executive offices)
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(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.
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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.
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Indicate by check mark whether the registrant is a large accelerated filer, an accelerated
filer, a non-accelerated filer, or a smaller reporting company. See definitions of large
accelerated filer, accelerated filer and smaller reporting company in Rule 12b-2 of the
Exchange Act. (Check one):
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Large accelerated filer
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Accelerated filer
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Non-accelerated filer
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Smaller reporting company
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(Do not check if a smaller reporting company)
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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, 2008, the Registrant had outstanding 100,949,485 shares of its Common Stock.
The aggregate market value of the Registrants voting stock held by non-affiliates at June 30, 2007
was approximately $10.48 billion, based on the closing price per share of Common Stock on June 29,
2007, the last trading day prior to that date, of $104.88 as reported on the New York Stock
Exchange, and at February 14, 2008 was approximately $8.13 billion, based on the closing price per
share of Common Stock on that date of $82.49 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
9, 2008 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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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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PART II
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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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16
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Item 6.
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Selected Financial Data
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19
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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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48
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Item 8.
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Financial Statements and Supplementary Data
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49
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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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82
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Item 9A.
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Controls and Procedures
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83
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Item 9B.
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Other Information
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85
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PART III
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Item 10.
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Directors and Executive Officers of the Registrant
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85
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Item 11.
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Executive Compensation
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85
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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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85
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Item 13.
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Certain Relationships and Related Transactions, and Director Independence
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86
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Item 14.
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Principal Accountant Fees and Services
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86
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PART IV
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Item 15.
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Exhibits, Financial Statements, Financial Statement Schedules
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86
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SIGNATURES
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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
electrical steel, tungsten-based materials and cutting tools, carbon alloy impression die forgings,
and large grey and ductile iron 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 focus our technological and unsurpassed 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 airframes and 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
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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 or supplement to gasoline and
other fossil fuels, and in liquefied natural gas (LNG).
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.
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)
and ductile iron castings 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 producing 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 also one of a few producers of very large ductile iron castings
used for wind turbines.
For electrical power distribution, our grain-oriented electrical steel (GOES) 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 the U.S. rebuilds its electrical energy distribution grid and as developing
countries, such as China and India, electrify and build electrical power distribution grids. The
U.S. Department of Energy (DOE) published its final rule on distribution transformer efficiency on
October 12, 2007, regarding minimum energy efficiency standard levels for electrical energy
distribution transformers beginning January 1, 2010. This DOE rule establishes requirements for
more efficient transformers, which increases premium grade GOES usage per transformer. ATI is a
leading producer of these premium grades of GOES.
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.
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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 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. In 2006 and 2007, we announced that we intended to spend at
least $950 million of internally generated funds to renew and expand our annual titanium sponge
production capabilities to approximately 46 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 $5.5 billion, $4.9 billion, and $3.5 billion for the years ended December 31,
2007, 2006, and 2005, respectively:
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2007
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2006
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2005
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High Performance Metals
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38
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%
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37
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35
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Flat-Rolled Products
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54
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54
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54
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Engineered Products
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9
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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 alloys, 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 alloys, and zirconium and hafnium alloys
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 electrical
steel. 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.
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Stainless steel, nickel-based alloys and titanium sheet products are used in a wide variety of
industrial and consumer applications. In 2007, approximately 60% by volume of our stainless sheet
products were sold to independent 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 2007, 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 2007, approximately 50% by volume of our plate products were sold to
independent service centers, with the remainder sold directly to end-use customers.
Grain-oriented electrical steel is used in power transformers where electrical conductivity
and magnetic properties are important. Nearly all of our grain-oriented electrical steel products
are sold directly to end-use customers.
Engineered Products Segment
The principal business of our Engineered Products segment includes the production of tungsten
powder, tungsten heavy alloys, tungsten carbide materials, and tungsten 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 ATI 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
|
Engineered Products segment Major Competitors
Tungsten and tungsten carbide products
|
|
|
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 presently 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, 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, in 2007 we used approximately 80 million pounds of nickel; therefore a
hypothetical increase of $1.00 per pound in nickel prices would result in increased costs of
approximately $80 million. We also used approximately 500 million pounds of ferrous scrap in the
production of our flat-rolled products in 2007 so that a hypothetical increase of $0.01 per pound
in ferrous scrap prices would result in increased costs of approximately $5 million.
While we are increasing our manufacturing capacity to produce titanium sponge, the major raw
material for our titanium products, a portion of our needs, together with certain other raw
materials, such as nickel, cobalt, and ferrochromium, are available to us and our specialty metals
industry competitors primarily from foreign sources. Some of these foreign sources are located in
countries that may be subject to unstable political and economic conditions, which might disrupt
supplies or affect the price of these materials.
We purchase our nickel requirements principally from producers in Australia, Canada, Norway,
Russia, and the Dominican Republic. Zirconium sponge is purchased from a source in France, while
zirconium sand is purchased from both U.S. and Australian sources. Cobalt is purchased primarily
from producers in Canada. More than 80% of the worlds reserves of ferrochromium are located in
South Africa, Zimbabwe, Albania, and Kazakhstan. We also purchase titanium sponge from sources in
Kazakhstan and Japan.
Export Sales and Foreign Operations
Direct international sales represented approximately 27% of our total annual sales in 2007, 24% of
our total sales in 2006, and approximately 25% of our total sales in 2005. These figures include
direct export sales by our U.S.-based operations to customers in foreign countries, which accounted
for approximately 19% of our total sales in 2007, and 16% of our total sales in each of 2006 and
2005. Our overseas sales, marketing and distribution efforts are aided by our international
marketing and distribution offices, ATI Europe, ATI Europe Distribution, and ATI Asia, or by
independent representatives located at various locations throughout the world. We believe that
nearly 50% of ATIs 2007 sales were driven by global markets when we consider exports of our
customers.
Direct sales by geographic area in 2007, and as a percentage of total sales, were as follows:
|
|
|
|
|
|
|
|
|
|
|
($ in millions)
|
|
|
|
|
|
|
|
|
|
|
|
United States
|
|
$
|
3,987.0
|
|
|
|
73%
|
|
|
Europe
|
|
|
864.7
|
|
|
|
16%
|
|
|
Far East
|
|
|
382.6
|
|
|
|
7%
|
|
|
Canada
|
|
|
138.9
|
|
|
|
3%
|
|
|
South America, Middle East and other
|
|
|
79.3
|
|
|
|
1%
|
|
|
|
|
Total sales
|
|
$
|
5,452.5
|
|
|
|
100%
|
|
|
|
ATI Allvac Ltd has manufacturing capabilities in the United Kingdom. ATI Metalworking
Products, 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.
8
Backlog, Seasonality and Cyclicality
Our backlog of confirmed orders was approximately $1.0 billion at December 31, 2007 and $1.2
billion at December 31, 2006. We expect that approximately 90% of confirmed orders on hand at
December 31, 2007 will be filled during the year ending December 31, 2008. Backlog of confirmed
orders of our High Performance Metals segment was approximately $683 million at December 31, 2007
and $730 million at December 31, 2006. We expect that approximately 85% of the confirmed orders on
hand at December 31, 2007 for this segment will be filled during the year ending December 31, 2008.
Backlog of confirmed orders of our Flat-Rolled Products segment was approximately $177 million at
December 31, 2007 and $353 million at December 31, 2006. We expect that all of the confirmed orders
on hand at December 31, 2007 for this segment will be filled during the year ending December 31,
2008.
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, 2007, 2006, and 2005 included the following:
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|
|
|
|
|
|
|
|
|
|
|
|
|
|
(In millions)
|
|
2007
|
|
|
2006
|
|
|
2005
|
|
|
|
|
Company-Funded:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
High Performance Metals
|
|
$
|
9.5
|
|
|
$
|
5.9
|
|
|
$
|
4.9
|
|
|
Flat-Rolled Products
|
|
|
1.9
|
|
|
|
1.5
|
|
|
|
1.4
|
|
|
Engineered Products
|
|
|
2.6
|
|
|
|
2.2
|
|
|
|
2.1
|
|
|
|
|
|
|
$
|
14.0
|
|
|
$
|
9.6
|
|
|
$
|
8.4
|
|
|
|
|
Customer-Funded:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
High Performance Metals
|
|
$
|
0.4
|
|
|
$
|
0.2
|
|
|
$
|
1.5
|
|
|
Flat-Rolled Products
|
|
|
0.1
|
|
|
|
0.3
|
|
|
|
0.2
|
|
|
|
|
|
|
$
|
0.5
|
|
|
$
|
0.5
|
|
|
$
|
1.7
|
|
|
|
|
Total Research and Development
|
|
$
|
14.5
|
|
|
$
|
10.1
|
|
|
$
|
10.1
|
|
|
|
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. We have a
comprehensive environmental management and reporting program that focuses on compliance with all
federal, state, regional and local environmental laws and regulations. Each
9
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.
Our
Corporate Guidelines for Business Conduct and Ethics
address compliance with environmental laws
as well as employment and workplace safety laws, and also describe our commitment to equal
opportunity and fair treatment of employees. We continued to realize significant progress in safety
across ATIs operations. As a result of our continuing focus on and commitment to safety, in 2007
our OSHA Total Recordable Incident Rate improved by 5% to 3.02 and our Lost Time Case Rate was
0.52, which we believe to be competitive with world class performance.
Employees
We have approximately 9,700 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 2,750 Allegheny Ludlum production, office and maintenance employees
covered by collective bargaining agreements that are effective through June 2011, approximately 325
Allvac Albany, Oregon (Oremet) employees covered by a collective bargaining agreement that is
effective through June 2011, approximately 630 Wah Chang employees covered by a collective
bargaining agreement that continues through March 2008, approximately 280 employees at our Casting
Service facility in LaPorte, Indiana, covered by a collective bargaining agreement that is
effective through December 2011, 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. We are negotiating a collective bargaining agreement with approximately 150
employees at our Rome Metals facilities.
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.
Executive Management, Including Executive Officers under Federal Securities Laws
The Companys executive officers under the federal securities laws and members of the Companys
management executive committee as of February 14, 2008 are as follows:
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|
|
|
|
|
|
|
|
|
|
Name
|
|
Age
|
|
Title
|
|
|
|
|
|
L. Patrick Hassey*
|
|
|
62
|
|
|
Chairman, President and Chief Executive Officer and Director
|
|
|
|
Richard J. Harshman*
|
|
|
51
|
|
|
Executive Vice President, Finance and Chief Financial Officer
|
|
|
|
Douglas A. Kittenbrink*
|
|
|
52
|
|
|
Executive Vice President, Corporate Planning and
International
Business Development
|
|
|
|
Jon D. Walton*
|
|
|
65
|
|
|
Executive Vice President, Human Resources, Chief Legal and
Compliance Officer, General Counsel and Corporate Secretary
|
|
|
|
Dale G. Reid*
|
|
|
52
|
|
|
Vice President, Controller, Chief Accounting Officer and
Treasurer
|
|
|
|
Terry L. Dunlap*
|
|
|
48
|
|
|
ATI Allegheny Ludlum Business Unit President
|
|
|
|
Thomas E. Williams**
|
|
|
67
|
|
|
ATI Allvac Business Unit President
|
|
|
|
Lynn Davis
|
|
|
59
|
|
|
ATI Wah Chang Business Unit President
|
|
|
|
David M. Hogan
|
|
|
61
|
|
|
ATI Metalworking Products Business Unit President and
Segment President, Engineered Products
|
|
|
|
|
|
|
|
*
|
|
Such individuals are subject to the reporting and other requirements of Section 16 of the
Securities Exchange Act of 1934, as amended.
|
10
|
|
|
|
|
**
|
|
Effective upon the retirement of Thomas E. Williams, on April 1, 2008, Hunter R. Dalton, 53,
will serve as ATI Allvac Business Unit President.
|
Set forth below are descriptions of the business background for the past five years of the
Companys executive management.
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, Corporate Planning and
International Business Development since March 1, 2007. Mr. Kittenbrink was Executive Vice
President, ATI Business System and Group President, Engineered Products Segment from October 2003
to March 2007. 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.
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.
Terry L. Dunlap
has served as ATI Allegheny Ludlum Business Unit President since November
2002.
Thomas E. Williams
has served as ATI Allvac Business Unit President since 1999. Mr. Williams
has announced his retirement from the Company effective March 31, 2008.
Lynn Davis
has served as ATI Wah Chang Business Unit President since September 2000.
David M. Hogan
has served as ATI Metalworking Products Business Unit President since 1997.
Since April 1, 2007, Mr. Hogan has also served as Segment President, Engineered Products.
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 potential uncertainty regarding
future profitability. Various changes in general economic conditions may affect the industries in
which our customers operate. These changes could include decreases in the rate of consumption or
use of our customers products due to economic downturns. Other factors that may cause 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.
11
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.
Although inflationary trends in recent years have been moderate, during the same period
certain critical raw material costs, such as nickel, titanium sponge, chromium, and molybdenum and
scrap containing iron, nickel, titanium, chromium, and molybdenum 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, was $33.83 in 2006 and
was $30.14 in 2007, 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, was $14.35 in 2006 and was $19.16 in
2007. 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, 2006, and 2007 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 2007, the decrease in raw material costs on the
LIFO inventory valuation method resulted in cost of sales which was $92.1 million lower than would
have been recognized if we utilized the first-in, first-out (FIFO) methodology to value our
inventory. Conversely 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 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. However, 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 33 of
such sites, excluding those at which we believe we have no future liability. Our involvement is
limited or de minimis at approximately 22 of these sites, and the potential loss exposure with
respect to any of the remaining 11 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, 2007, our reserves for environmental matters
totaled approximately $20 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 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, government contracting work, employment, employee benefits, taxes,
environmental,
13
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 9,700 full-time employees. A portion of our workforce is
covered by various collective bargaining agreements, principally with the USW, including:
approximately 2,750 Allegheny Ludlum production, office and maintenance employees covered by
collective bargaining agreements, which are effective through June 2011; approximately 325 Allvac
Albany, Oregon (Oremet) employees covered by a collective bargaining agreement, which is effective
through June 2011; approximately 630 Wah Chang employees covered by a collective bargaining
agreement, which continues through March 2008, approximately 280 employees at the Casting Service
facility in LaPorte, Indiana, covered by a collective bargaining agreement, which is effective
through December 2011, 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.
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.
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 Retirement Benefits.
Our U.S. qualified defined benefit pension plan was
fully 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, 2007. 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
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.
14
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.
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 began 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.
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 and Alpena, MI (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.
15
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 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 resolved this matter by paying a civil penalty of $65,000 in
March 2007.
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 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 13. 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, Related Stockholder Matters and Issuer
Repurchases of Equity Securities
Common Stock Prices
Our common stock is traded on the New York Stock Exchange (symbol ATI). At February 14, 2008, there
were approximately 5,577 record holders of Allegheny Technologies Incorporated common stock. We
paid a quarterly cash dividend of $0.13 per share of common stock for each of the first three
quarters of 2007. In the fourth quarter of 2007, our Board of Directors increased the quarterly
cash dividend paid on our common stock by nearly 40% to $0.18 per share. This was the third
consecutive year that ATI has significantly increased its dividend. During the first three quarters
of 2006, we paid a quarterly cash dividend of $0.10 per share. In the fourth quarter of 2006, our
Board of Directors increased the cash dividend paid on our common stock to $0.13 per share. The
ranges of high and low sales prices for shares of our common stock for the periods indicated were
as follows:
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Quarter Ended
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March 31
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June 30
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September 30
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December 31
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2007
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|
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|
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High
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$
|
110.00
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|
$
|
119.70
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|
|
$
|
116.25
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$
|
115.55
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Low
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$
|
85.10
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|
$
|
99.17
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$
|
80.00
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$
|
82.59
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March 31
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June 30
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September 30
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December 31
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2006
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High
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$
|
61.39
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|
$
|
84.53
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|
$
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69.33
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|
$
|
98.20
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Low
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|
$
|
36.05
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|
$
|
57.00
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|
|
$
|
55.82
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|
|
$
|
60.30
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16
Purchases of Equity Securities by the Issuer and Affiliated Purchasers
Set forth below is information regarding the Companys stock repurchases during the period covered
by this report
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Approximate Dollar
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Total Number of
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Value of Shares that
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Shares Purchased as Part
|
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May Yet Be
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Total Number of
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Average Price
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of Publicly Announced
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Purchased Under the
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Period
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Shares Purchased
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Paid per Share
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Plans or Programs
(2)
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Plans or Programs
(2)
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January 1-31, 2007 (1)
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500,828
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$
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98.98
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February 1-28, 2007
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March 1-31, 2007
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Quarter ended March 31, 2007 (1)
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500,828
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|
$
|
98.98
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April 1-30, 2007 (1)
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4,246
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|
|
$
|
115.85
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|
|
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May 1-31, 2007
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June 1-30, 2007
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|
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|
|
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Quarter ended June 30, 2007 (1)
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4,246
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|
|
$
|
115.85
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July 1-31, 2007
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August 1-31, 2007
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September 1-30, 2007
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Quarter ended September 30, 2007
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October 1-31, 2007
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November 1-30, 2007 (2)
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108,600
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$
|
90.44
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108,600
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$
|
490,178,000
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December 1-31, 2007 (2)
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566,200
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|
|
|
90.79
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|
|
|
566,200
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|
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438,773,000
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|
|
|
|
Quarter ended December 31, 2007 (2)
|
|
|
674,800
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|
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$
|
90.73
|
|
|
|
674,800
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|
|
$
|
438,773,000
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(1)
|
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Represents shares repurchased by ATI to satisfy employee-owed taxes on share-based payments.
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(2)
|
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Includes purchases under ATIs publicly announced share repurchase program described in (3)
below. All purchases were made in the open market.
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(3)
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ATIs Board of Directors approved a share repurchase program of $500 million on November 1,
2007. Repurchases of Company stock are expected to be made on the open market or in
unsolicited or privately negotiated transactions. Share repurchases are expected to be funded
from internal cash flow and cash on hand. The number of shares to be purchased, and the timing
of the purchases, will be based on several factors, including the level of cash balances,
general business conditions, and other investment opportunities.
|
17
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, 2002 through December 31, 2007 as
compared to the S&P 500 Index, and a Peer Group of companies. We believe the Peer Group of
companies, which is defined below, is representative of companies in our industry that serve
similar markets. 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, 2002.
Comparison of Cumulative Five Year Total Return
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Base Period
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Company / Index
|
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|
Dec 02
|
|
|
|
Dec 03
|
|
|
|
Dec 04
|
|
|
|
Dec 05
|
|
|
|
Dec 06
|
|
|
|
Dec 07
|
|
|
Allegheny Technologies
|
|
|
100.00
|
|
|
|
221.80
|
|
|
|
368.81
|
|
|
|
620.18
|
|
|
|
1,568.46
|
|
|
|
1,502.83
|
|
|
S&P 500 Index
|
|
|
100.00
|
|
|
|
128.68
|
|
|
|
142.69
|
|
|
|
149.70
|
|
|
|
173.34
|
|
|
|
182.86
|
|
|
Peer Group
|
|
|
100.00
|
|
|
|
165.78
|
|
|
|
182.33
|
|
|
|
198.46
|
|
|
|
257.44
|
|
|
|
339.95
|
|
Source: Standard & Poors
Peer Group companies for the cumulative five year total return period ended December 31, 2007 were
as follows:
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|
|
|
|
|
AK Steel Holding Corp.
|
|
Quanex Corp.
|
|
ALCAN Inc.*
|
|
Reliance Steel & Aluminum Co.
|
|
ALCOA Inc.
|
|
RTI International Metals Inc.
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|
Carpenter Technology Corp.
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|
Steel Dynamics Inc.
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|
IPSCO Inc.*
|
|
Titanium Metals Corp.
|
|
Kennametal Inc.
|
|
United States Steel Corp.
|
|
Nucor Corp.
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|
18
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, 2007, 2006 and 2005. 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.
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|
|
For the Years Ended December 31,
|
|
2007
|
|
|
2006
|
|
|
2005
|
|
|
2004
|
|
|
2003
|
|
|
|
|
Volume (000s lbs.):
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
High Performance Metals titanium mill products
|
|
|
30,689
|
|
|
|
27,361
|
|
|
|
24,882
|
|
|
|
22,012
|
|
|
|
18,436
|
|
|
High Performance Metals nickel-based and
specialty alloys
|
|
|
44,688
|
|
|
|
42,873
|
|
|
|
39,939
|
|
|
|
34,353
|
|
|
|
35,168
|
|
|
High Performance Metals exotic alloys
|
|
|
5,169
|
|
|
|
4,304
|
|
|
|
4,018
|
|
|
|
4,318
|
|
|
|
4,245
|
|
|
Flat-Rolled Products:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
High value
|
|
|
491,891
|
|
|
|
502,524
|
|
|
|
495,868
|
|
|
|
508,946
|
|
|
|
470,500
|
|
|
Standard
|
|
|
557,016
|
|
|
|
889,105
|
|
|
|
652,870
|
|
|
|
666,560
|
|
|
|
486,206
|
|
|
|
|
|
Flat-Rolled Products total
|
|
|
1,048,907
|
|
|
|
1,391,629
|
|
|
|
1,148,738
|
|
|
|
1,175,506
|
|
|
|
956,706
|
|
|
Average Prices (per lb.):
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
High Performance Metals titanium mill products
|
|
$
|
30.14
|
|
|
$
|
33.83
|
|
|
$
|
22.75
|
|
|
$
|
12.34
|
|
|
$
|
11.50
|
|
|
High Performance Metals nickel-based and
specialty alloys
|
|
|
19.16
|
|
|
|
14.35
|
|
|
|
11.25
|
|
|
|
8.60
|
|
|
|
6.57
|
|
|
High Performance Metals exotic alloys
|
|
|
41.85
|
|
|
|
40.39
|
|
|
|
40.38
|
|
|
|
40.95
|
|
|
|
37.64
|
|
|
Flat-Rolled Products:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
High value
|
|
|
3.22
|
|
|
|
2.50
|
|
|
|
2.15
|
|
|
|
1.67
|
|
|
|
1.36
|
|
|
Standard
|
|
|
2.40
|
|
|
|
1.61
|
|
|
|
1.26
|
|
|
|
1.18
|
|
|
|
0.83
|
|
|
Flat-Rolled Products combined average
|
|
|
2.79
|
|
|
|
1.93
|
|
|
|
1.64
|
|
|
|
1.39
|
|
|
|
1.09
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(In millions)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
For the Years Ended December 31,
|
|
2007
|
|
|
2006
|
|
|
2005
|
|
|
2004
|
|
|
2003
|
|
|
|
|
Sales:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
High Performance Metals
|
|
$
|
2,067.6
|
|
|
$
|
1,806.6
|
|
|
$
|
1,246.0
|
|
|
$
|
794.1
|
|
|
$
|
641.7
|
|
|
Flat-Rolled Products
|
|
|
2,951.9
|
|
|
|
2,697.3
|
|
|
|
1,900.5
|
|
|
|
1,643.9
|
|
|
|
1,043.5
|
|
|
Engineered Products
|
|
|
433.0
|
|
|
|
432.7
|
|
|
|
393.4
|
|
|
|
295.0
|
|
|
|
252.2
|
|
|
|
|
Total sales
|
|
$
|
5,452.5
|
|
|
$
|
4,936.6
|
|
|
$
|
3,539.9
|
|
|
$
|
2,733.0
|
|
|
$
|
1,937.4
|
|
|
|
|
Operating profit (loss):
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
High Performance Metals
|
|
$
|
729.1
|
|
|
$
|
657.2
|
|
|
$
|
335.1
|
|
|
$
|
86.0
|
|
|
$
|
25.8
|
|
|
Flat-Rolled Products
|
|
|
505.2
|
|
|
|
348.0
|
|
|
|
154.1
|
|
|
|
62.8
|
|
|
|
(13.2
|
)
|
|
Engineered Products
|
|
|
32.1
|
|
|
|
56.7
|
|
|
|
47.5
|
|
|
|
20.8
|
|
|
|
7.8
|
|
|
|
|
Total operating profit
|
|
$
|
1,266.4
|
|
|
$
|
1,061.9
|
|
|
$
|
536.7
|
|
|
$
|
169.6
|
|
|
$
|
20.4
|
|
|
|
|
Income (loss) before income taxes and cumulative effect of
change in accounting principle
|
|
$
|
1,147.3
|
|
|
$
|
872.6
|
|
|
$
|
311.1
|
|
|
$
|
22.3
|
|
|
$
|
(279.7
|
)
|
|
Income (loss) before cumulative effect of change in accounting
principle
|
|
|
747.1
|
|
|
|
574.1
|
|
|
|
364.4
|
|
|
|
21.4
|
|
|
|
(313.0
|
)
|
|
Cumulative effect of change in accounting principle, net of tax
|
|
|
|
|
|
|
|
|
|
|
(2.0
|
)
|
|
|
|
|
|
|
(1.3
|
)
|
|
|
|
Net income (loss)
|
|
$
|
747.1
|
|
|
$
|
574.1
|
|
|
$
|
362.4
|
|
|
$
|
21.4
|
|
|
$
|
(314.3
|
)
|
|
|
|
Basic net income (loss) per common share:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Income (loss) before cumulative effect of change in accounting
principle
|
|
$
|
7.35
|
|
|
$
|
5.76
|
|
|
$
|
3.79
|
|
|
$
|
0.25
|
|
|
$
|
(3.90
|
)
|
|
Cumulative effect of change in accounting principle
|
|
|
|
|
|
|
|
|
|
|
(0.02
|
)
|
|
|
|
|
|
|
(0.02
|
)
|
|
|
|
Basic net income (loss) per common share
|
|
$
|
7.35
|
|
|
$
|
5.76
|
|
|
$
|
3.77
|
|
|
$
|
0.25
|
|
|
$
|
(3.92
|
)
|
|
|
|
Diluted net income (loss) per common share:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Income (loss) before cumulative effect of change in accounting
principle
|
|
$
|
7.26
|
|
|
$
|
5.61
|
|
|
$
|
3.61
|
|
|
$
|
0.24
|
|
|
$
|
(3.90
|
)
|
|
Cumulative effect of change in accounting principle
|
|
|
|
|
|
|
|
|
|
|
(0.02
|
)
|
|
|
|
|
|
|
(0.02
|
)
|
|
|
|
Diluted net income (loss) per common share
|
|
$
|
7.26
|
|
|
$
|
5.61
|
|
|
$
|
3.59
|
|
|
$
|
0.24
|
|
|
$
|
(3.92
|
)
|
|
|
19
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(In millions except per share amounts and ratios)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
As of and for the Years Ended December 31,
|
|
2007
|
|
|
2006
|
|
|
2005
|
|
|
2004
|
|
|
2003
|
|
|
|
|
Dividends declared per common share
|
|
$
|
0.57
|
|
|
$
|
0.43
|
|
|
$
|
0.28
|
|
|
$
|
0.24
|
|
|
$
|
0.24
|
|
|
|
|
Ratio of earnings to fixed charges
|
|
|
25.0x
|
|
|
|
18.1x
|
|
|
|
6.5x
|
|
|
|
1.4x
|
|
|
|
|
|
|
|
|
Working capital
|
|
$
|
1,544.7
|
|
|
$
|
1,344.8
|
|
|
$
|
926.1
|
|
|
$
|
670.2
|
|
|
$
|
350.5
|
|
|
|
|
Total assets
|
|
|
4,095.6
|
|
|
|
3,280.5
|
|
|
|
2,729.9
|
|
|
|
2,315.4
|
|
|
|
1,903.6
|
|
|
|
|
Long-term debt
|
|
|
507.3
|
|
|
|
529.9
|
|
|
|
547.0
|
|
|
|
553.3
|
|
|
|
504.3
|
|
|
|
|
Total debt
|
|
|
528.2
|
|
|
|
553.6
|
|
|
|
560.4
|
|
|
|
582.7
|
|
|
|
532.1
|
|
|
|
|
Cash and cash equivalents
|
|
|
623.3
|
|
|
|
502.3
|
|
|
|
362.7
|
|
|
|
250.8
|
|
|
|
79.6
|
|
|
|
|
Stockholders equity
|
|
|
2,223.5
|
|
|
|
1,502.9
|
|
|
|
808.0
|
|
|
|
431.4
|
|
|
|
178.6
|
|
|
|
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 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.
Stockholders equity for 2007 included a $71.4 million net increase to adjust pension and
other postretirement liabilities in accordance with Statement of Financial Accounting Standards No.
158, Employers Accounting for Defined Benefit Pension and Other Postretirement Plans and a $50.7
million increase for the tax benefit on stock-based compensation. In addition, stockholders
equity for 2007 was reduced by $61.2 million for the repurchases of the Companys common stock.
Stockholders equity for 2006 included a $47 million net increase to adjust pension and other
postretirement liabilities, and an $81 million increase for the tax benefit on stock-based
compensation. Stockholders equity for 2005 included 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 included $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
included 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.
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
year ended December 31, 2003, fixed charges exceeded earnings by $280.2 million.
In the 2007 first quarter, as required, the Company adopted Financial Accounting Standards
Board (FASB) Staff Position (FSP) titled Accounting for Planned Major Maintenance Activities
(FSP PMMA). The FSP PMMA was effective as of the beginning of ATIs 2007 fiscal year, with
retrospective application to all prior periods presented. The adoption of the FSP PMMA on January
1, 2007 resulted in an increase to retained earnings of $10.3 million, net of related taxes. As
required by the FSP PMMA, the Companys financial statements have been restated to reflect this FSP
as if this standard had been applied to the earliest period presented. As a result, net income for
2006, 2005 and 2004 increased $2.2 million, $2.6 million and $1.6 million, respectively.
In the 2007 first quarter, as required, the Company also adopted 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 was effective for the beginning of ATIs 2007 fiscal
year, with adoption treated as a cumulative-effect type reduction to retained earnings of $5.6
million as of the beginning of 2007.
In the 2005 fourth quarter, the Company adopted FASB Interpretation No. 47, Accounting for
Conditional Asset Retirement Obligations (FIN 47), an interpretation of Statement of Financial
Accounting Standards No. 143, Asset Retirement Obligations (FAS 143). Net income for 2005
included a charge for the cumulative effect of adopting FIN 47 of $2.0 million net of related tax
effects. The Company adopted FAS 143 on January 1, 2003. The cumulative effect of adoption of FAS
143 was a $1.3 million charge net of related tax effects. 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 2007 Financial Performance
In 2007, we strengthened our position in key global growth markets, launched new production
facilities, and solidified our balance sheet while achieving record sales and profits. Net income
for the full year 2007 increased 30% to $747.1 million, or $7.26 per share, compared to $574.1
million, or $5.61 per share, for 2006. For 2007, return on capital employed was 31.2%, and return
on stockholders equity was 40.1%. Sales increased 10.5% to $5.45 billion for 2007. Direct
international sales increased $294.8 million, or 25%, and represented 27% of our total sales. Our
growth is being driven by demand from the aerospace and defense market and strong demand from those
markets that are vital to the building and rebuilding of the global infrastructure. For 2007, 31%
of our sales were to the aerospace and defense market, 24% to the chemical process industry and oil
and gas markets, 13% to the electrical energy market, and 3% to the medical market. These major
high-value growing global markets represented 71% of ATIs 2007 sales.
In our High Performance Metals segment, year-over-year sales increased 14% to $2.07 billion
due primarily to demand from the aerospace and defense, and oil and gas markets for our titanium
and titanium alloys, nickel-based alloys and superalloys, and vacuum melted specialty alloys. In
addition, sales benefited from the 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 $729.1 million, an 11% increase compared
to 2006, due primarily to higher shipments resulting from increased demand, higher average selling
prices for nickel-based alloys, specialty alloys and exotic alloys, and benefits from our gross
cost reduction efforts. Lower raw material costs, primarily titanium scrap, resulted in a LIFO
inventory valuation benefit of $96.3 million for 2007 compared to a LIFO inventory valuation charge
in 2006 of $49.4 million.
In our Flat-Rolled Products segment, sales increased 9% to $2.95 billion primarily as a result
of improved product mix, higher average base selling prices and raw material surcharges. While
demand for our specialty and titanium sheet, and grain-oriented electrical steel products was
strong from the global electrical energy, oil and gas, and chemical process industry markets,
shipments of our standard stainless products declined primarily due to U.S. and European service
center customers destocking actions, and concerns by other customers due to the volatility of raw
material surcharges as a result of the extreme volatility in the cost of nickel throughout most of
2007. Total Flat-Rolled Products shipments declined 25%, with shipments of standard stainless
products declining 37%. Even with the decline in shipments, operating profit for the Flat-Rolled
Products segment was a record $505.2 million, a 45% increase compared to 2006. This improvement in
2007 operating profit was due primarily to improved product mix, higher average base selling
prices, and the benefits from our gross cost reduction efforts. Increased raw material costs,
partially offset by lower inventory quantities, resulted in a LIFO inventory valuation charge of
$1.9 million for 2007 compared to a LIFO inventory valuation charge of $147.3 million in 2006.
In our Engineered Products segment, 2007 sales were comparable to prior year at $433.0
million. However, operating profit declined to $32.1 million, compared to $56.7 million in 2006,
primarily due to higher purchased raw material costs, and start-up costs associated with our newly
expanded ammonium paratungstate (APT) plant, including the slower than planned ramp-up of this
plant.
For 2007, total segment operating profit increased 19% to $1.27 billion, an increase of $204.5
million compared to 2006. Total segment operating profit as a percentage of total sales reached a
record 23.2% in 2007, compared to 21.5% in 2006.
During 2007, 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 continuing to drive lean manufacturing throughout our operations. Our accomplishments
during 2007 from these important efforts included:
|
|
|
We continued to grow our global market presence as direct international sales reached a
record $1.47 billion, or 27% of total sales, an increase of $294.8 million compared to 2006.
We believe that nearly 50% of ATIs 2007 sales were driven by global markets when we consider
exports of our customers.
|
|
|
|
|
|
We continued to build a foundation for further profitable growth. During second half 2007, we
entered into additional long-term agreements with customers for our titanium and titanium
alloy, nickel-based alloy, specialty alloy, grain-oriented electrical steel, and iron castings
products. These contracts build upon agreements announced earlier in 2007 and in the second
half of 2006 with
|
21
|
|
|
The Boeing Company and GE Aviation to supply these aerospace and defense customers with titanium
and nickel-based superalloys. We believe these agreements indicate that long-term supply of these
products remained critically important to our customers.
|
|
|
|
|
|
We continued to realize significant benefits of our strategic focus for high value specialty
products, especially titanium. In 2007, shipments of titanium products, including ATI produced
products for our Uniti titanium joint venture, increased 15% to approximately 41 million
pounds. For 2008, we currently expect shipments of titanium products to increase an additional
25% to over 50 million pounds. These volume increases are being achieved utilizing our
manufacturing capabilities across both our High Performance Metals and Flat-Rolled Products
segments and demonstrate our ability to supply the marketplace with both long and flat-rolled
products.
|
|
|
|
|
|
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. During the past three years, we
have invested over $800 million, of which $457.1 million was spent in 2007, to expand our
titanium sponge production, and our melting, rolling and finishing capabilities. Our 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
achieved an annualized production rate of approximately 16 million pounds at the end of
2007, and is expected to reach approximately 22 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 estimated cost of this facility is expected to be approximately $460
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 46 million pounds, and is intended to supplement
our purchased titanium sponge and purchased titanium scrap requirements. The Utah facility
could be expanded to a total annual capacity of 42 million pounds with additional capital
investment if market conditions warrant such an investment.
|
|
|
|
|
|
|
The design and construction of a titanium alloys and nickel-based alloys and superalloy
forging facility at our operations in North Carolina at an estimated cost of $237 million.
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 and into 2010.
|
|
|
|
|
|
|
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 the second quarter of 2008.
|
|
|
|
|
|
|
A significant expansion of our capability to produce ammonium paratungstate (APT), a
raw material used in the production of tungsten powder and tungsten-based cutting tools and
other products in our Engineered Products segment. This investment was completed in 2007
and is now fully operational. 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.
|
|
|
|
|
|
|
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.
|
For 2008, we currently plan to spend approximately $500 million for capital expenditures,
excluding the capital expansion underway at our STAL joint venture.
22
|
|
|
We realized strong cash generation in 2007. Cash on hand at the end of 2007 was $623 million,
an increase of $121 million compared to the end of 2006. This increase in cash is after
investing $457 million in capital expenditures and purchases of businesses, $44 million in
managed working capital due primarily to higher business activity, $100 million in a voluntary
cash contribution to our U.S. qualified defined benefit pension plan, $61 million to
repurchase ATI stock, and $58 million in dividend payments.
|
|
|
|
|
|
We continued to strengthen our balance sheet. At the end of 2007, ATI had more cash than
debt. Therefore, our net debt to total capitalization improved to a negative 4.5% compared to
a positive 3.3%, 19.7%, 43.5% and 71.7% at year-end 2006, 2005, 2004 and 2003, respectively.
Total debt to total capital declined to 19.2% compared to 26.9%, 41.0%, 57.5%, and 74.9% at
year-end 2006, 2005, 2004, and 2003, respectively. At the end of 2007, our U.S. qualified
defined benefit pension plan was 111% funded. This is significant as the funded status of the
plan prior to 2006 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 $29
million in 2008, compared to 2007.
|
|
|
|
|
|
We continued to realize significant progress in safety across ATIs operations. As a result
of our continuing focus on and commitment to safety, in 2007 our OSHA Total Recordable
Incident Rate improved by 5% to 3.02 and our Lost Time Case Rate was 0.52, which we believe to
be competitive with world class performance.
|
|
|
|
|
|
We realized continued success from the ATI Business System, which is continuing to drive lean
manufacturing throughout our operations. In addition to the improved safety performance
discussed above, we realized $112 million in gross cost reductions in 2007 which exceeded our
goal of $100 million. We have targeted additional gross cost reductions of $100 million in
2008.
|
|
|
|
|
|
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 nearly 40% to $0.18 per share in November 2007. This is
the third consecutive year the Board has significantly increased the dividend. Additionally
in November 2007, the Board of Directors authorized a $500 million share repurchase program.
|
As a result of these accomplishments, we believe our long-term profitable growth outlook
remains intact. With our new production capabilities and our strong financial position, we believe
ATI is well positioned to continue to expand our presence in the growing global markets that have
been driving our performance over the last several years. We expect demand from the commercial
aerospace market to remain at a high level as our airframe and jet engine customers backlogs are
at record levels. We also expect demand from the chemical process industry, oil and gas, and
electrical energy markets to stay strong as the global infrastructure build and rebuild continues.
Results of Operations
Sales were $5.45 billion in 2007, $4.94 billion in 2006 and $3.54 billion in 2005. Direct
international sales represented approximately 27% of 2007 sales, 24% of 2006 sales and 25% of 2005
sales.
Segment operating profit was $1.27 billion in 2007, $1.06 billion in 2006, and $536.7 million
in 2005. 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 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 $1.15
billion in 2007, $872.6 million in 2006, and $311.1 million in 2005. 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.
Net income was $747.1 million for 2007, $574.1 million for 2006, and $362.4 million for 2005.
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 impairment charges in the Flat-Rolled Products
segment, charges for legal matters, and the cumulative effect of adopting a new accounting
principle for conditional asset retirement obligations.
23
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:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
2007
|
|
|
2006
|
|
|
2005
|
|
|
|
|
|
|
|
|
Operating
|
|
|
|
|
|
|
Operating
|
|
|
|
|
|
|
Operating
|
|
|
|
|
Revenue
|
|
|
Profit
|
|
|
Revenue
|
|
|
Profit
|
|
|
Revenue
|
|
|
Profit
|
|
High Performance Metals
|
|
|
38
|
%
|
|
|
58
|
%
|
|
|
37
|
%
|
|
|
62
|
%
|
|
|
35
|
%
|
|
|
62
|
%
|
|
|
|
|
|
Flat-Rolled Products
|
|
|
54
|
%
|
|
|
40
|
%
|
|
|
54
|
%
|
|
|
33
|
%
|
|
|
54
|
%
|
|
|
29
|
%
|
|
|
|
|
|
Engineered Products
|
|
|
8
|
%
|
|
|
2
|
%
|
|
|
9
|
%
|
|
|
5
|
%
|
|
|
11
|
%
|
|
|
9
|
%
|
|
|
|
|
Information with respect to our business segments is presented below and in Note 9 of the
Notes to Consolidated Financial Statements.
High Performance Metals
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(In millions)
|
|
2007
|
|
|
% Change
|
|
|
2006
|
|
|
% Change
|
|
|
2005
|
|
|
|
|
Sales to external customers
|
|
$
|
2,067.6
|
|
|
|
14
|
%
|
|
$
|
1,806.6
|
|
|
|
45
|
%
|
|
$
|
1,246.0
|
|
|
|
|
Operating profit
|
|
|
729.1
|
|
|
|
11
|
%
|
|
|
657.2
|
|
|
|
96
|
%
|
|
|
335.1
|
|
|
|
|
Operating profit as a percentage of sales
|
|
|
35.3
|
%
|
|
|
|
|
|
|
36.4
|
%
|
|
|
|
|
|
|
26.9
|
%
|
|
|
|
Direct international sales as a percentage of sales
|
|
|
32.0
|
%
|
|
|
|
|
|
|
31.3
|
%
|
|
|
|
|
|
|
32.3
|
%
|
|
|
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, electrical energy and medical. The operating units in this segment are ATI
Allvac, ATI Allvac Ltd (U.K.) and ATI Wah Chang.
2007 Compared to 2006
Sales for the High Performance Metals segment for 2007 increased 14% to $2.07 billion, due
primarily to improved volume and higher average selling prices for our nickel-based alloys and
superalloys, vacuum-melted specialty alloys, and exotic alloy products driven by increased demand
from the aerospace and defense, oil and gas, chemical process industry, and electrical energy
markets. Our direct international sales increased $94.5 million, or 17%, to $660.8 million, and
represented 32% of sales for the High Performance Metals segment. Comparative information on the
segments products for the years ended December 31, 2007 and 2006 was:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
For the Years Ended December 31,
|
|
2007
|
|
2006
|
|
% Change
|
|
|
|
Volume (000s lbs.):
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Titanium mill products
|
|
|
30,689
|
|
|
|
27,361
|
|
|
|
12
|
%
|
|
Nickel-based and specialty steel alloys
|
|
|
44,688
|
|
|
|
42,873
|
|
|
|
4
|
%
|
|
Exotic alloys
|
|
|
5,169
|
|
|
|
4,304
|
|
|
|
20
|
%
|
|
|
|
Average Prices (per lb.):
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Titanium mill products
|
|
$
|
30.14
|
|
|
$
|
33.83
|
|
|
|
(11
|
%)
|
|
Nickel-based and specialty steel alloys
|
|
$
|
19.16
|
|
|
$
|
14.35
|
|
|
|
34
|
%
|
|
Exotic alloys
|
|
$
|
41.85
|
|
|
$
|
40.39
|
|
|
|
4
|
%
|
|
|
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 announced a long-term sourcing agreement
with GE Aviation for the supply of premium titanium alloys, nickel-based superalloys, and
vacuum-melted specialty alloys 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 alloys products for Boeings aircraft airframes and
structural components, including Boeings 787 Dreamliner. Total revenues under this contract are
expected to be 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
24
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 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), is expected to require approximately
250,000 pounds of titanium alloys mill products per aircraft, a significant increase over any
previous commercial aircraft airframe. 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
record backlogs of both Boeing and Airbus, and the engine manufacturers, this increasing demand for
titanium alloys mill products is expected to last into the next decade.
Annually, revenue passenger miles and freight miles have increased 8.8% and 7.4%,
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 5.4% 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
|
|
07
|
|
Revenue Passenger Miles (Billions)
|
|
|
286
|
|
|
|
433
|
|
|
|
676
|
|
|
|
849
|
|
|
|
1,176
|
|
|
|
1,396
|
|
|
|
1,887
|
|
|
|
2,311
|
|
|
|
2,609
|
|
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
|
|
07
|
|
Freight Ton-Miles (Billions)
|
|
|
8
|
|
|
|
13
|
|
|
|
20
|
|
|
|
27
|
|
|
|
40
|
|
|
|
57
|
|
|
|
81
|
|
|
|
98
|
|
|
|
110
|
|
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
|
|
|
2011
|
|
|
Boeing deliveries
|
|
271
|
|
|
374
|
|
|
563
|
|
|
620
|
|
|
491
|
|
|
527
|
|
|
381
|
|
|
281
|
|
|
285
|
|
|
290
|
|
|
398
|
|
|
441
|
|
|
485
|
|
|
535
|
|
|
600
|
|
|
585
|
|
|
Airbus deliveries
|
|
126
|
|
|
182
|
|
|
229
|
|
|
294
|
|
|
311
|
|
|
325
|
|
|
303
|
|
|
305
|
|
|
320
|
|
|
378
|
|
|
434
|
|
|
453
|
|
|
520
|
|
|
595
|
|
|
620
|
|
|
605
|
|
|
Regional jet del.
|
|
54
|
|
|
92
|
|
|
137
|
|
|
193
|
|
|
293
|
|
|
325
|
|
|
300
|
|
|
308
|
|
|
309
|
|
|
260
|
|
|
183
|
|
|
179
|
|
|
205
|
|
|
175
|
|
|
140
|
|
|
135
|
|
|
Military A/C del.
|
|
129
|
|
|
193
|
|
|
205
|
|
|
175
|
|
|
130
|
|
|
113
|
|
|
128
|
|
|
160
|
|
|
243
|
|
|
243
|
|
|
253
|
|
|
228
|
|
|
243
|
|
|
237
|
|
|
240
|
|
|
287
|
|
|
|
|
|
|
Total deliveries
|
|
580
|
|
|
841
|
|
|
1,134
|
|
|
1,282
|
|
|
1,225
|
|
|
1,290
|
|
|
1,112
|
|
|
1,054
|
|
|
1,157
|
|
|
1,171
|
|
|
1,268
|
|
|
1,301
|
|
|
1,453
|
|
|
1,542
|
|
|
1,600
|
|
|
1,612
|
|
High Performance Metals segment operating profit for 2007 increased 11% to $729.1 million
compared to 2006 primarily due to higher volume, higher average selling prices for many of our
products, and improved product mix. Segment results in 2007 and 2006 were affected by volatile raw
material costs. Nickel and nickel-bearing scrap, and titanium scrap increased significantly in
2006 and the first half of 2007, but declined sharply in the 2007 second half. These material costs
are largely recovered in product selling prices through raw material indices which attempt to match
purchased material costs with shipments. However in an environment of rapidly increasing, or
declining costs, these raw material indices included in product selling prices may not completely
offset purchased material costs. The rapid fall in raw material costs in the 2007 second half had a
significant negative effect on operating profit as shipments produced with raw material purchased
earlier in the year at higher costs were sold based upon raw material indices which reflected lower
raw material prices. This negative impact on operating profit was offset by a LIFO inventory
valuation reserve benefit of $96.3 million. In 2006, higher nickel, nickel-bearing scrap, and
titanium raw material costs resulted in a LIFO inventory valuation reserve charge of $49.4 million.
27
We continued to aggressively reduce costs in 2007. Gross cost reductions, before the effects of
inflation, totaled approximately $42 million. Major areas of gross cost reductions included $26
million from procurement, $11 million from operating efficiencies, and $5 million from salaried and
hourly labor cost savings.
To support our strategic growth initiatives in the High Performance Metals segment, we have
committed to significantly expand our manufacturing capabilities. Under projects announced in the
past three years, we expect to spend approximately $885 million, of which approximately $355
million has been spent as of December 31, 2007. These projects include a multi-phase titanium
products expansion that is expected to yield up to 46 million pounds of annual titanium sponge
production capacity, an increase in ATIs annual titanium melt capacity by at least 25 million
pounds, and expansion of our forging and finishing operations for titanium and titanium alloys,
nickel-based alloys and superalloys, and vacuum-melted specialty alloys. These strategic capital
investments are designed to expand and enhance ATIs capacity 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.
In the first quarter 2007, we entered into a new labor agreement, which expires on June 30,
2011, with the United Steelworkers represented at ATIs Allvac Albany, Oregon operations. As a
result of this new agreement, we recognized a non-recurring pre-tax charge of $0.7 million.
2006 Compared to 2005
Sales for the High Performance Metals segment increased 45% to $1.81 billion in 2006 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. Our exotic alloys business continued to benefit from demand from the
aerospace, defense, chemical processing, and medical 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.):
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Titanium mill products
|
|
|
27,361
|
|
|
|
24,882
|
|
|
|
10
|
%
|
|
Nickel-based and specialty steel alloys
|
|
|
42,873
|
|
|
|
39,939
|
|
|
|
7
|
%
|
|
Exotic alloys
|
|
|
4,304
|
|
|
|
4,018
|
|
|
|
7
|
%
|
|
|
|
Average Prices (per lb.):
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Titanium mill products
|
|
$
|
33.83
|
|
|
$
|
22.75
|
|
|
|
49
|
%
|
|
Nickel-based and specialty steel alloys
|
|
$
|
14.35
|
|
|
$
|
11.25
|
|
|
|
28
|
%
|
|
Exotic alloys
|
|
$
|
40.39
|
|
|
$
|
40.38
|
|
|
|
|
%
|
|
|
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 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 $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, for 2006 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.
Flat-Rolled Products
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(In millions)
|
|
2007
|
|
|
% Change
|
|
|
2006
|
|
|
% Change
|
|
|
2005
|
|
|
|
|
Sales to external customers
|
|
$
|
2,951.9
|
|
|
|
9
|
%
|
|
$
|
2,697.3
|
|
|
|
42
|
%
|
|
$
|
1,900.5
|
|
|
|
|
Operating income
|
|
|
505.2
|
|
|
|
45
|
%
|
|
|
348.0
|
|
|
|
126
|
%
|
|
|
154.1
|
|
|
|
|
Operating income as a percentage of sales
|
|
|
17.1
|
%
|
|
|
|
|
|
|
12.9
|
%
|
|
|
|
|
|
|
8.1
|
%
|
|
|
|
Direct international sales as a percentage of sales
|
|
|
23.1
|
%
|
|
|
|
|
|
|
18.1
|
%
|
|
|
|
|
|
|
18.7
|
%
|
|
|
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 electrical steel sheet, and tool steels. The major end markets for our flat-rolled
products are electrical energy, oil and gas, chemical processing, automotive, food processing
equipment and appliances, construction and mining, electronics,
28
communication equipment and computers, and aerospace and defense. 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.
2007 Compared to 2006
Sales for the Flat-Rolled Products segment for 2007 were $2.95 billion, or 9% higher than 2006, due
primarily to higher average raw material surcharges and increased average base prices for most
products, especially titanium and grain-oriented electrical steel products, and improved product
mix, partially offset by a significant reduction in shipments of standard stainless products.
Comparative information on the segments products for the years ended December 31, 2007 and 2006
was:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
For the Years Ended December 31,
|
|
2007
|
|
|
2006
|
|
|
|
% Change
|
|
|
|
Volume (000s lbs.):
|
|
|
|
|
|
|
|
|
|
|
|
|
|
High value
|
|
|
491,891
|
|
|
|
502,524
|
|
|
|
(2
|
%)
|
|
Standard
|
|
|
557,016
|
|
|
|
889,105
|
|
|
|
(37
|
%)
|
|
|
|
|
|
Total Flat-Rolled Products
|
|
|
1,048,907
|
|
|
|
1,391,629
|
|
|
|
(25
|
%)
|
|
|
|
Average Prices (per lb.):
|
|
|
|
|
|
|
|
|
|
|
|
|
|
High value
|
|
$
|
3.22
|
|
|
$
|
2.50
|
|
|
|
29
|
%
|
|
Standard
|
|
$
|
2.40
|
|
|
$
|
1.61
|
|
|
|
49
|
%
|
|
Total Flat-Rolled Products
|
|
$
|
2.79
|
|
|
$
|
1.93
|
|
|
|
44
|
%
|
|
|
Total shipments in 2007 decreased by 25% to 1,049 million pounds compared to shipments of
1,392 million pounds for 2006. The average transaction prices to customers, which includes the
effect of higher average raw material surcharges, increased by 44% to $2.79 per pound in 2007. Our
direct international sales increased $192.2 million, or 39%, to $680.4 million, and represented 23%
of sales for the Flat-Rolled Products segment. While the majority of direct international sales
were for high-value products, sales of standard products, primarily stainless steel cold roll
sheet, increased to $145 million dollars.
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 electrical steel, and tool steel products, decreased 2% while average
transaction prices for our high-value products increased 29%. Strong demand for our nickel-based
alloy, titanium, and grain-oriented electrical steel products from the chemical process industry,
oil and gas, and electrical energy markets was offset by lower demand for our engineered strip,
Precision Rolled Strip®, and super stainless steel products. Shipments of titanium and ATI-produced
Uniti titanium products grew nearly 25% to approximately 10.4 million pounds, and shipments of our
grain-oriented electrical steel grew 5%, both compared to 2006.
Shipments of our standard products, which primarily include stainless steel hot roll and cold
roll sheet, and stainless steel plate, decreased 37% while average transaction prices for these
products increased 50%. In 2007, consumption in the U.S. of stainless steel strip, sheet and plate
products decreased by more than 17%, compared to 2006 consumption, according to the Specialty Steel
Institute of North America (SSINA). The decrease in shipments was primarily attributable to
inventory adjustments by service center customers primarily for stainless steel sheet. Our
The
Switch is On
marketing campaign had its best year ever in 2007 as customers in both the U.S. and
Europe recognized the value of lean nickel products, such as AL201HP stainless, which has
approximately one-half the nickel content as the most common Type 304 stainless product with
similar corrosion properties and greater strength. In 2007, shipments of AL201HP stainless
increased over 57% compared to 2006.
29
Apparent Domestic Consumption
Stainless Sheet and Strip
(Millions of tons)
|
*
|
|
2007 represents November YTD, annualized
|
Apparent Domestic Consumption
Stainless Sheet and Strip
(Millions of tons)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
00
|
|
|
|
01
|
|
|
|
02
|
|
|
|
03
|
|
|
|
04
|
|
|
|
05
|
|
|
|
06
|
|
|
|
07
|
|
|
Millions/Tons
|
|
|
1.88
|
|
|
|
1.55
|
|
|
|
1.58
|
|
|
|
1.57
|
|
|
|
1.81
|
|
|
|
1.62
|
|
|
|
1.84
|
|
|
|
1.53
|
|
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 nickel, iron, chromium, and molybdenum. Nickel, which comprises a significant
percentage of our material costs, continued to be volatile during 2007. The cost of nickel
increased 51% during the first five months of 2007 to an average monthly cost of $23.63 per pound
in May 2007. However, during the next seven months of 2007, the cost of nickel declined 50% to an
average monthly cost of $11.79 per pound in December 2007. While the rapid run-up in nickel costs
increased our average transactional selling prices for 2007, we believe the volatility of these
costs had a negative effect on our shipment volumes, as customers reduced the amount of material
that was held in stock and altered their normal purchasing pattterns.
30
Iron Scrap Prices
($/Gross Ton)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
97
|
|
|
98
|
|
|
|
99
|
|
|
|
00
|
|
|
|
01
|
|
|
|
02
|
|
|
|
03
|
|
|
|
04
|
|
|
|
05
|
|
|
|
06
|
|
|
|
07
|
|
|
144
|
|
|
83
|
|
|
|
129
|
|
|
|
85
|
|
|
|
74
|
|
|
|
105
|
|
|
|
173
|
|
|
|
233
|
|
|
|
255
|
|
|
|
229
|
|
|
|
297
|
|
Nickel Prices
($/lb)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
97
|
|
|
98
|
|
|
|
99
|
|
|
|
00
|
|
|
|
01
|
|
|
|
02
|
|
|
|
03
|
|
|
|
04
|
|
|
|
05
|
|
|
|
06
|
|
|
|
07
|
|
|
2.70
|
|
|
1.76
|
|
|
|
3.67
|
|
|
|
3.32
|
|
|
|
2.69
|
|
|
|
3.26
|
|
|
|
6.43
|
|
|
|
6.25
|
|
|
|
6.09
|
|
|
|
15.68
|
|
|
|
11.79
|
|
Source: London Metals Exchange
31
Chromium Prices
($/lb)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
97
|
|
98
|
|
|
99
|
|
|
00
|
|
|
01
|
|
|
02
|
|
|
03
|
|
|
04
|
|
|
05
|
|
|
06
|
|
|
07
|
|
|
0.49
|
|
0.40
|
|
|
0.39
|
|
|
0.41
|
|
|
0.29
|
|
|
0.35
|
|
|
0.54
|
|
|
0.69
|
|
|
0.54
|
|
|
0.66
|
|
|
1.71
|
|
Source: Platts Metals Week
Molybdenum Oxide
($/lb)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
97
|
|
98
|
|
|
99
|
|
|
00
|
|
|
01
|
|
|
02
|
|
|
03
|
|
|
04
|
|
|
05
|
|
|
06
|
|
|
07
|
|
|
3.69
|
|
2.57
|
|
|
2.56
|
|
|
2.23
|
|
|
2.36
|
|
|
3.26
|
|
|
7.26
|
|
|
31.24
|
|
|
26.58
|
|
|
24.78
|
|
|
32.38
|
|
Source: Platts Metals Week
32
Operating income increased $157.2 million, or 45%, to $505.2 million for 2007, compared to
2006. The benefits of higher average base-selling prices, improved product mix and the benefits
from our gross cost reduction initiatives, offset significantly lower shipments. During 2007, the
average cost of our raw materials in our Flat-Rolled Products segment increased approximately 6%
compared to the 2006 average cost. These increased costs, largely offset by lower inventory
quantities, resulted in a LIFO inventory valuation charge of $1.9 million for 2007 compared to a
LIFO inventory valuation reserve charge of $147.3 million in 2006.
We continued to aggressively reduce costs and streamline our operations. In 2007, we achieved
gross cost reductions, before the effects of inflation, of approximately $60 million in our
Flat-Rolled Products segment. Major areas of gross cost reductions included $28 million from
operating efficiencies, $24 million from procurement savings, and $8 million from lower
compensation and fringe benefit expenses.
In the first quarter 2007, we entered into a new labor agreement with the United Steelworkers
represented at ATIs Allegheny Ludlum operations. The new agreement expires on June 30, 2011. The
new agreement provides for profit sharing above specified minimum pre-tax profit for the
Flat-Rolled Products segment and is capped to provide for no more than $20 million of profit
sharing payments under this provision over the four-year life of the contract. Any profit sharing
payments under this provision are contributed to an independently administered VEBA (Voluntary
Employee Benefit Association) trust. As a result of this new agreement, we recognized a
non-recurring pre-tax charge of $4.8 million.
To support our strategic growth initiatives in the Flat-Rolled Products segment, we committed
to significantly expand our manufacturing capabilities in certain areas. In January 2007, we
announced the expansion of ATI Allegheny Ludlums titanium and specialty plate facility located in
Washington, PA. The purpose of this capital investment is to meet growing demand for our products
from the aerospace and defense, chemical process industry, oil and gas, and electrical energy
markets. This investment benefits both our Flat-Rolled Products and High Performance Metals
segments. We expect this investment to be approximately $60 million with completion planned for the
end of the second quarter 2008. The titanium and specialty plate capital project includes
increasing reheat and annealing furnace, and flattening capacity at the existing plate mill. In
addition, our plate size capabilities are being expanded and significant productivity improvements
are expected to be realized.
In 2006, we 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 which has been made
by ATI, bank credit lines of the joint venture, and cash on hand and the internal cash flow of the
joint venture.
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
|
%
|
|
Standard
|
|
|
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
|
%
|
|
Standard
|
$
|
1.61
|
|
$
|
|
1.26
|
|
|
|
28
|
%
|
|
Total Flat-Rolled Products
|
$
|
1.93
|
|
$
|
|
1.64
|
|
|
|
18
|
%
|
|
|
Our Flat-Rolled Products segment high-value product shipments, which include engineered strip,
Precision Rolled Strip®, super stainless steel, nickel-based alloys, titanium, grain-oriented
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 electrical steel, 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
33
products, increased $134.7 million, or 38%, to $485.6 million, and represented a record 18.0%
of sales for the Flat-Rolled Products segment.
Shipments of standard 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 14%, compared to 2005 consumption, according to the Specialty Steel
Institute of North America (SSINA). Demand was strong for our standard products from the biofuel
(ethanol) and construction markets and was good from the appliance and appliance related markets.
Operating income increased to $348.0 million for 2006 compared to $154.1 million in 2005. The
benefits of increased sales volume, higher average base-selling prices, cost reduction initiatives,
and additional surcharges offset a significantly higher LIFO inventory valuation reserve charge 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 approximately $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.
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.
Engineered Products
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(In millions)
|
|
2007
|
|
% Change
|
|
2006
|
|
% Change
|
|
2005
|
|
|
|
Sales to external customers
|
|
$
|
433.0
|
|
|
|
|
%
|
|
$
|
432.7
|
|
|
|
10
|
%
|
|
$
|
393.4
|
|
|
|
|
Operating profit
|
|
|
32.1
|
|
|
|
(43
|
%)
|
|
|
56.7
|
|
|
|
19
|
%
|
|
|
47.5
|
|
|
|
|
Operating profit as a percentage of sales
|
|
|
7.4
|
%
|
|
|
|
|
|
|
13.1
|
%
|
|
|
|
|
|
|
12.1
|
%
|
|
|
|
Direct international sales as a percentage of sales
|
|
|
28.7
|
%
|
|
|
|
|
|
|
26.8
|
%
|
|
|
|
|
|
|
28.6
|
%
|
|
|
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 ATI Rome Metals.
The major markets served by our products of the Engineered Products Segment include a wide
variety of industrial markets including oil and gas, machine and cutting tools, transportation,
construction and mining, electrical energy, aerospace and defense, and automotive.
2007 Compared to 2006
Sales for the Engineered Products segment in 2007 were $433.0 million, comparable to 2006 sales.
Demand for our tungsten and tungsten-carbide products improved from the aerospace and defense, and
cutting tool markets, but was lower from the oil and gas market for down-hole drilling
applications. Demand was strong for our forged products from the construction and mining, and oil
and gas markets and demand was soft from the transportation market. Demand for our cast products
was strong from the electrical energy market for wind and natural gas power generation
applications. Demand remained strong for our titanium precision metal processing conversion
services, primarily due to the aerospace market.
Segment operating profit in 2007 was $32.1 million, or 7.4% of sales, compared to $56.7
million, or 13.1% of sales for 2006. The decline in operating profit was primarily due to higher
purchased raw material costs, start-up costs associated with our newly expanded ammonium
paratungstate (APT) plant, and the slower than planned ramp-up of this plant. In 2007, we commenced
commercial operations at the new APT plant, a $17 million capital investment that began in the 2005
fourth quarter. The new APT plant allows us to expand our production capacity to internally source
all of our APT and cobalt requirements at what is expected to be
34
significantly lower costs than purchased material. Operating profit included a LIFO inventory
valuation reserve charge of $2.3 million in 2007, and a charge of $0.3 million in 2006 as a result
of higher raw material costs and inventory levels.
During 2007, in addition to the APT plant expansion, we continued to invest in order to
enhance our manufacturing capabilities and reduce costs. In 2007, we invested $6.5 million to
expand our titanium precision metal conversion services operation as part of our continuing
strategic program to increase our overall titanium production capacity to better meet growing
global demand, primarily from the aerospace market. In addition, during the third quarter 2007, we
acquired production assets in Alpena, MI to manufacture and machine large iron castings to support
our growth in the wind energy market. The cost of acquiring these assets was $9.7 million. It is
expected that these assets will be put into service over the first half of 2008.
In 2007, we achieved gross cost reductions, before the effects of inflation, of approximately
$9 million in our Engineered Products segment. Major areas of gross cost reductions included $5
million from operating efficiencies, $3 million from procurement savings, and $1 million from lower
compensation and fringe benefit expenses.
2006 Compared to 2005
Sales in 2006 for the Engineered Products segment 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.
Corporate Expenses
Corporate expenses were 1.4% of sales, or $73.8 million, in 2007 compared to 1.4% of sales, or
$68.9 million, in 2006 and 1.5% of sales, or $51.7 million, in 2005. The increase in corporate
expenses in 2007 and 2006 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 and interest capitalization, was $4.8 million for 2007
compared to $23.3 million for 2006, and $38.6 million for 2005. Interest expense is presented net
of interest income of $26.0 million for 2007, $15.0 million for 2006, and $8.4 million for 2005.
The increase in interest income for 2007 and 2006 primarily results from higher cash balances.
Increased capital expenditures associated with strategic investments to expand our production
capabilities resulted in higher interest capitalization in 2007 and 2006. Interest expense in 2007,
2006, and 2005 was reduced by $9.8 million, $4.5 million, and $0.2 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 (Notes), which were later settled, resulting in
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 $1.8 million in 2007, $1.7
million in 2006, and $1.5 million in 2005 due to these previously settled interest rate swap
agreements.
Restructuring Costs
We had no restructuring costs in 2007 or 2006.
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
35
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.
At December 31, 2007, approximately $2 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 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 consolidated statements of income and resulted in
net charges of $10.2 million in 2007 and $15.2 million in 2006, and other income of $33.8 million
in 2005.
Other expenses for 2007 and 2006 primarily related to legal costs associated with closed
operations. For 2005, other expenses included $26.8 million for legal matters, which were paid in
2006 and are classified in selling and administrative expenses in the consolidated statement of
income, and $7.0 million for environmental and other closed company costs.
Retirement Benefit Expense
Retirement benefit expense, which includes pension and postretirement medical benefits, has
declined since 2004 primarily due to actual returns on plan assets exceeding expected returns, and
the positive benefits of voluntary pension contributions totaling $350 million over past four
years. Retirement benefit expense was $30.3 million for 2007, $81.9 million for 2006, and $77.6
million for 2005. 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 2007, 2006 and 2005 was as follows:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(In millions)
|
|
2007
|
|
|
2006
|
|
|
2005
|
|
|
|
|
Cost of sales
|
|
$
|
20.3
|
|
|
$
|
55.3
|
|
|
$
|
55.1
|
|
|
Selling and administrative expenses
|
|
|
10.0
|
|
|
|
26.6
|
|
|
|
22.5
|
|
|
|
|
Total retirement benefit expense
|
|
$
|
30.3
|
|
|
$
|
81.9
|
|
|
$
|
77.6
|
|
|
|
Total retirement benefit expense for 2008 is expected to be approximately $1.0 million, a
decline of $29.3 million compared to 2007. This decrease is primarily attributable to the pension
component of retirement benefit expense. As a result of higher than expected returns on pension
assets in 2007 and the benefits of the $100 million voluntary contribution to the U.S. qualified
defined benefit pension plan made in the 2007 fourth quarter, we expect pension income for 2008 to
be approximately $13.0 million compared to pension expense of $17.1 million for 2007.
Postretirement medical expense, the other component of retirement benefit expense, is expected to
increase to approximately $14.0 million in 2008, compared to $13.2 million in 2007, primarily as a
result of lower plan assets in 2008 as benefit payments are expected to reduce VEBA trust assets.
Income Taxes
Results of operations for 2007 included a provision for income taxes of $400.2 million, or 34.9% of
income before tax, for U.S. Federal, foreign and state income taxes. The results for 2007 benefited
from a $23.1 million reduction of a deferred tax valuation allowance with respect to certain state
tax credits expected to be realized in future periods. Results of operations for 2006 included a
provision for income taxes of $298.5 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
$53.3 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. From the 2003 fourth quarter through the third quarter of 2005, we maintained a
valuation allowance for a major portion of our U.S. Federal deferred tax assets and certain state
deferred tax assets in accordance with FAS 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
36
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.
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, 2007, we had a net deferred
tax asset of $60.9 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 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 senior unsecured credit facility, or former facility during 2007, 2006 or 2005, although
a portion has been 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, 2007, Moodys Investor Services
senior unsecured debt rating for our Company was Baa3 with a stable ratings outlook. On February
11, 2008, Standard & Poors Ratings Services raised our corporate credit and senior unsecured debt
ratings to BBB- with a stable ratings 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 2007, cash generated by operations of $809.8 million and the proceeds from the exercises of
stock options of $5.5 million were used to invest $457.1 million in capital expenditures and
purchases of businesses, fund a $100 million voluntary contribution to our U.S. qualified defined
benefit pension plan, purchase $61.2 million of the Companys common stock, pay dividends of $58.1
million, repay debt of $23.9 million, and increase cash balances by $121.0 million to $623.3
million at December 31, 2007. In 2006, cash generated by operations of $411.6 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 $238.3 million in capital expenditures, 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 from operations of $323.8 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 $91.3 million in capital expenditures, fund a $100 million voluntary
contribution to our U.S. 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 $362.7 million at December 31, 2005. We use cash flow
from operations before voluntary pension plan contributions in order to evaluate and compare fiscal
periods that do not include these contributions, and to make resource allocation decisions among
operational requirements, investing and financing alternatives.
37
Managed Working Capital
($ Millions)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
03
|
|
04
|
|
05
|
|
06
|
|
07
|
|
Millions/$
|
|
|
576
|
|
|
|
853
|
|
|
|
1,048
|
|
|
|
1,582
|
|
|
|
1,627
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
% of Annualized Revenue
|
|
|
30.7
|
%
|
|
|
29.5
|
%
|
|
|
30.3
|
%
|
|
|
29.0
|
%
|
|
|
32.2
|
%
|
In 2007 and 2006, the favorable impact of improved operating results 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 2007, managed working capital, which we define as gross inventory plus accounts receivable
less accounts payable, increased $44.3 million. This increase resulted from a $41.1 million
increase in accounts receivable due to the timing of sales in the fourth quarter 2007 compared to
the fourth quarter 2006, and a $36.2 million increase in inventory, mostly as a result of increased
operating volumes particularly for the High Performance Metals segment products, partially offset
by a $33.0 million increase in accounts payable. During 2006, managed working capital increased by
$534.2 million. This increase resulted from a $166.5 million increase in accounts receivable due to
a higher level of sales in the 2006 fourth quarter compared to the fourth quarter of 2005, and a
$409.2 million increase in inventory, mostly as a result of increased operating volumes and higher
raw materials costs, partially offset by a $41.5 million increase in accounts payable. Managed
working capital has increased approximately $1.1 billion over the past five years as our level of
business activity and raw material costs have both 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 increased to 32.2% at the end of
2007, compared to 29.0% at the end of 2006, and 30.3% in 2005. The increase in 2007 of managed
working capital as a percentage of sales was primarily due to a shift in mix to more value added
products, primarily in the High Performance Metals and Flat-Rolled Products business segments,
which have a longer manufacturing process. While accounts receivable balances increased during this
three year period, days sales outstanding, which measures actual collection timing for accounts
receivable, have improved.
38
The components of managed working capital were as follows:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
December 31,
|
|
|
December 31,
|
|
|
December 31,
|
|
|
(In millions)
|
|
2007
|
|
|
2006
|
|
|
2005
|
|
|
|
|
Accounts receivable, net
|
|
$
|
652.2
|
|
|
$
|
610.9
|
|
|
$
|
442.1
|
|
|
Inventory, net
|
|
|
916.1
|
|
|
|
798.7
|
|
|
|
607.1
|
|
|
Accounts payable
|
|
|
(388.4
|
)
|
|
|
(355.1
|
)
|
|
|
(312.9
|
)
|
|
|
|
Subtotal
|
|
|
1,179.9
|
|
|
|
1,054.5
|
|
|
|
736.3
|
|
|
Allowance for doubtful accounts
|
|
|
6.3
|
|
|
|
5.7
|
|
|
|
8.1
|
|
|
LIFO reserve
|
|
|
374.6
|
|
|
|
466.7
|
|
|
|
269.7
|
|
|
Corporate and other
|
|
|
65.7
|
|
|
|
55.3
|
|
|
|
33.9
|
|
|
|
|
Managed working capital
|
|
$
|
1,626.5
|
|
|
$
|
1,582.2
|
|
|
$
|
1,048.0
|
|
|
|
|
Annualized prior 2 months sales
|
|
$
|
5,058.5
|
|
|
$
|
5,453.5
|
|
|
$
|
3,461.1
|
|
|
|
|
Managed working capital as a % of sales
|
|
|
32.2
|
%
|
|
|
29.0
|
%
|
|
|
30.3
|
%
|
|
|
Capital expenditures for 2007 were $447.4 million, compared to $238.3 million in 2006, and
$91.3 million in 2005.
We are significantly expanding our manufacturing capabilities to meet current and expected
demand growth from the aerospace (engine and airframe) and defense, chemical process industry, oil
and gas, electrical energy, and medical markets, especially for titanium and titanium-based alloys,
nickel-based alloys and superalloys, specialty alloys, and exotic alloys. These self-funded capital
investments remain on track to be completed as planned and include:
|
§
|
|
The expansion of ATIs aerospace quality titanium sponge production capabilities, including
our titanium sponge facility in Albany, OR, and our greenfield premium-grade titanium sponge
(jet engine rotating parts) facility in Rowley, UT. Twelve titanium sponge reduction furnaces
at Albany, OR are now in operation, bringing our current annual titanium sponge capacity at
this facility to approximately 16 million pounds. When the full expansion of the Albany
facility is completed by mid-2008, we expect that this facility will be capable of producing
22 million pounds annually of aerospace quality titanium sponge and represent a total capital
investment of approximately $100 million. The Rowley, UT sponge facility remains on schedule
and will represent a total capital investment of approximately $460 million. We expect to
begin producing premium-grade titanium sponge at the Utah facility by the end of 2008, with 24
million pounds of annual capacity to be reached by the fourth quarter of 2009. Upon
completion of these titanium sponge expansion projects, our annual sponge production capacity
is projected to be 46 million pounds. In addition, the Utah facility will have the
infrastructure in place to further expand annual capacity by approximately 18 million pounds,
bringing the total annual capacity at that facility to 42 million pounds, if needed. We expect
to supplement our requirements with titanium sponge and titanium scrap purchases from external
sources.
|
|
|
|
§
|
|
The expansion of ATIs melting capabilities for titanium and titanium-based alloys,
nickel-based alloys and superalloys, and specialty alloys. For titanium melting, three new
vacuum-arc remelt (VAR) furnaces are on line, and we plan to have two more titanium VAR
furnaces customer qualified by the end of the first quarter 2008. VAR melting is a consumable
electrode re-melting process that improves the cleanliness and chemical homogeneity of the
alloys. Our third Plasma Arc Melt (PAM) premium titanium melt furnace is in production and
has completed initial customer qualifications. We expect to have this PAM furnace qualified
for all products, including premium grade jet engine rotating quality products, during the
second quarter 2008. A fourth PAM furnace to support premium titanium alloy growth
requirements is expected to begin production by the third quarter 2009. 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. We also expect one new
vacuum-arc remelt (VAR) furnace for nickel-based alloys and superalloys to be qualified and in
commercial production by the first quarter of 2008, with up to three more VARs to be added
through 2009 based on production requirements to support titanium and titanium-based alloys
and premium nickel-based alloys and superalloys growth.
|
|
|
|
§
|
|
The expansion of ATIs mill products processing and finishing capabilities for titanium and
titanium-based alloys, nickel-based alloys and superalloys, and specialty alloys. Announced
projects include expanding titanium precision metal processing conversion capacity, which was
completed in the third quarter 2007, and a $260 million expansion of our titanium and
superalloy forging capacity at our Bakers, NC facility through the addition of an integrated
10,000 ton press forge, 700mm rotary forge, and conditioning, finishing and inspection
facilities to support increased forged product requirements, which 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. We also are investing $60 million to
expand our titanium and specialty plate facility located in Washington, PA, which is expected
to begin production 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,
|
39
|
|
|
and common austenitic stainless grades. This project includes increasing reheat furnace,
annealing, and flattening capacity at the existing plate mill, expanding plate size
capabilities, and implementing productivity improvements.
|
|
|
|
§
|
|
We are increasing our zirconium sponge production capacity by approximately 20%. In
addition, we have diverted two new VAR furnaces to zirconium melting. These two VARs were
originally planned for titanium melting. This new zirconium sponge and melting capacity
better positions ATI for the strong nuclear electrical energy and chemical process industry
markets.
|
The above-described strategic growth capital projects represent approximately $985 million of
self-funded capital investments, approximately $435 million of which had already been expended
through 2007. We currently expect that our projected 2008 capital expenditures will be
approximately $500 million, including expenditures for the completion of the above-mentioned
strategic capital projects as well as other potential growth capital projects.
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 rolling and slitting capacity to produce Precision Rolled
Strip® products, 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 of the joint venture, and cash on
hand and internal cash flow of the joint venture. Our cash contribution to this expansion was $24.8
million, of which one-half was contributed by ATI in the 2006 third quarter, and the remainder in
March 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 consolidated
statements of income and as a liability in the consolidated statements of financial position.
Debt
Total debt outstanding decreased $25.4 million, to $528.2 million at December 31, 2007, from $553.6
million at December 31, 2006. The decrease was primarily related to reduced net borrowings at our
foreign operations and scheduled debt maturity payments. In managing our overall capital structure,
some of the measures on which we focus are net debt to total capitalization, which is the
percentage of our debt, net of cash that may be available to reduce borrowings, to our total
invested and borrowed capital, and total debt to total capitalization, which excludes cash
balances. At December 31, 2007, our cash on hand exceeded our total debt. Therefore our net debt
to total capitalization was a negative 4.5% compared to a positive 3.3% at December 31, 2006, 19.7%
at December 31, 2005, and 43.5% at December 31, 2004. Total debt to total capitalization improved
to 19.2% at December 31, 2007 compared to 26.9% at December 31, 2006, 41.0% at December 31, 2005,
and 57.5% at December 31, 2004. The continuing improvement in these ratios during 2007 is due
primarily from increases in cash on hand and stockholders equity resulting from the improvement in
results of operations.
|
|
|
|
|
|
|
|
|
|
|
|
|
December 31,
|
|
|
December 31,
|
|
|
(In millions)
|
|
2007
|
|
|
2006
|
|
|
|
|
Total debt
|
|
$
|
528.2
|
|
|
$
|
553.6
|
|
|
Less: Cash
|
|
|
(623.3
|
)
|
|
|
(502.3
|
)
|
|
|
|
Net debt
|
|
$
|
(95.1
|
)
|
|
$
|
51.3
|
|
|
|
|
|
|
|
|
|
|
|
|
Net debt
|
|
$
|
(95.1
|
)
|
|
$
|
51.3
|
|
|
Total stockholders equity
|
|
|
2,223.5
|
|
|
|
1,502.9
|
|
|
|
|
Total capital
|
|
$
|
2,128.4
|
|
|
$
|
1,554.2
|
|
|
Net debt to capital ratio
|
|
|
(4.5
|
%)
|
|
|
3.3
|
%
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
December 31,
|
|
|
December 31,
|
|
|
(In millions)
|
|
2007
|
|
|
2006
|
|
|
|
|
Total debt
|
|
$
|
528.2
|
|
|
$
|
553.6
|
|
|
Total stockholders equity
|
|
|
2,223.5
|
|
|
|
1,502.9
|
|
|
|
|
Total capital
|
|
$
|
2,751.7
|
|
|
$
|
2,056.5
|
|
|
Total debt to total capital ratio
|
|
|
19.2
|
%
|
|
|
26.9
|
%
|
|
|
On July 31, 2007, we replaced our then-existing $325 million senior secured domestic revolving
credit facility, which was due to expire in August 2010, with a new five-year $400 million senior
unsecured domestic revolving credit facility. The unsecured facility includes a $200 million
sublimit for the issuance of letters of credit. Under the unsecured facility, the Company may
increase the size of the facility by up to $100 million without seeking the further approval of the
lending group. The unsecured facility requires us to maintain a leverage ratio (consolidated total
indebtedness divided by consolidated earnings before interest, taxes and depreciation and
40
amortization) of not greater than 3.25, and maintain an interest coverage ratio (consolidated
earnings before interest and taxes divided by interest expense) of not less than 2.0. For the year
ended December 31, 2007, our leverage ratio was 0.46, and our interest coverage ratio was 37.36. We
have not borrowed funds under the senior unsecured domestic facility, or former facility, during
2007, although a portion has been utilized to support the issuance of letters of credit.
Outstanding letters of credit issued under the unsecured facility at December 31, 2007, were
approximately $43 million, compared to $120 million at the end of 2006.
The ratio of earnings to fixed charges for the three and twelve month periods ended December
31, 2007 was 20.8 and 25.0, respectively.
In August 2007, STAL, our Chinese joint venture company in which ATI has a 60% interest,
entered into a five year revolving credit facility with a group of banks. Under the credit
facility, STAL may borrow up to 741 million renminbi (approximately $99 million at December 2007
exchange rates) at an interest rate equal to 90% of the applicable lending rate published by the
Peoples Bank of China. The credit facility is supported solely by STALs financial capability
without any guarantees from the joint venture partners, and is intended to be utilized in the
future for the expansion of STALs operations, which are located in Shanghai, China. The credit
facility requires STAL to maintain a minimum level of shareholders equity, and certain financial
ratios. As of December 31, 2007, there had been no borrowings made under this credit facility.
STAL had approximately $20.5 million in letters of credit outstanding as of December 31, 2007.
These letters of credit are supported solely by STALs financial capability without any guarantees
from the joint venture partners.
Interest rate swap contracts have been used from time-to-time to manage our exposure to
interest rate risks. At December 31, 2007, 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. 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 four
years. At December 31, 2007, the deferred settlement gain was $8.7 million. The result of the
receive fixed, pay floating arrangements was a decrease in interest expense of $1.8 million, $1.7
million and $1.5 million for the years ended December 31, 2007, 2006 and 2005, 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
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|
|
4-5
|
|
|
After 5
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|
|
(In millions)
|
|
Total
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|
|
1 year
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|
|
years
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|
|
years
|
|
|
years
|
|
|
|
|
Contractual Cash Obligations
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|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total Debt including Capital Leases
|
|
$
|
522.8
|
|
|
$
|
20.9
|
|
|
$
|
34.5
|
|
|
$
|
312.5
|
|
|
$
|
154.9
|
|
|
Operating Lease Obligations
|
|
|
66.7
|
|
|
|
16.9
|
|
|
|
28.5
|
|
|
|
17.7
|
|
|
|
3.6
|
|
|
Other Long-term Liabilities (A)
|
|
|
191.2
|
|
|
|
|
|
|
|
61.9
|
|
|
|
10.5
|
|
|
|
118.8
|
|
|
Unconditional Purchase Obligations
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|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Raw materials (B)
|
|
|
1,978.7
|
|
|
|
758.4
|
|
|
|
784.5
|
|
|
|
93.2
|
|
|
|
342.6
|
|
|
Capital expenditures
|
|
|
144.7
|
|
|
|
137.7
|
|
|
|
7.0
|
|
|
|
|
|
|
|
|
|
|
Other (C)
|
|
|
48.1
|
|
|
|
18.0
|
|
|
|
18.8
|
|
|
|
9.4
|
|
|
|
1.9
|
|
|
|
|
Total
|
|
$
|
2,952.2
|
|
|
$
|
951.9
|
|
|
$
|
935.2
|
|
|
$
|
443.3
|
|
|
$
|
621.8
|
|
|
|
|
|
|
(In millions)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Other Financial Commitments
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|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Lines of Credit (D)
|
|
$
|
577.5
|
|
|
$
|
48.2
|
|
|
$
|
49.9
|
|
|
$
|
479.4
|
|
|
$
|
|
|
|
Guarantees
|
|
|
27.1
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(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, 2007, 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.
41
(D) Drawn amounts were $17.7 million at December 31, 2007 under foreign credit agreements, and
drawn amounts are included in total debt. Drawn amounts also include $43.1 million utilized under
the $400 million domestic senior unsecured credit facility for standby letters of credit, which
renew annually and are used to support: $27.8 million in workers compensation and general
insurance arrangements, and $15.3 million related to environmental, legal and other matters.
Retirement Benefits
The value of the investments in our U.S. qualified defined benefit pension plan exceeded pension
plan liabilities as of November 30, 2007, our measurement date for accounting purposes, by $230
million, or approximately 11%. We have not been required to make cash contributions to this defined
benefit pension plan since 1995. However, during the past four years, we have made $350 million in
voluntary cash contributions to this plan to improve the plans funded position. These voluntary
contributions were comprised of cash contributions of $100 million during the fourth quarter of
2007, 2006 and 2005, respectively, and $50 million during the third quarter 2004. 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. However, 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 2007, 2006,
and 2005, we funded $30.8 million, $28.1 million, and $24.7 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 $76 million as of November 30, 2007, our measurement date for accounting
purposes.
Dividends
We paid a quarterly dividend of $0.13 per share of common stock for each of the first three
quarters of 2007. In the fourth quarter of 2007, our Board of Directors increased the quarterly
cash dividend paid on our common stock by nearly 40% to $0.18 per share. This was the third
consecutive year that ATI has significantly increased its dividend. 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 law, credit agreements or senior securities, and other factors deemed
relevant and appropriate.
Share Repurchase Program
On November 1, 2007, our Board of Directors approved a share repurchase program of $500 million.
Repurchases of Company common stock are expected to be made on the open market or in unsolicited or
privately negotiated transactions. Share repurchases are expected to be funded from internal cash
flow and cash on hand. The number of shares to be purchased, and the timing of the purchases, will
be based on several factors, including the level of cash balances, general business conditions, and
other investment opportunities. As of December 31, 2007, 674,800 shares of common stock had been
purchased under this program at a cost of $61.2 million.
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.
42
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 $6.3 million at December 31, 2007 and $5.7 million at
December 31, 2006, which represented 1.0% and 0.9%, respectively, of total gross accounts
receivable. During 2007, we recognized expense of $1.0 million to increase the reserve for doubtful
accounts and wrote off $0.4 million of uncollectible accounts, which reduced the reserve. 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.
Inventories
At December 31, 2007, we had net inventory of $916.1 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 rise in raw material costs has a negative effect on our
operating results, while, conversely, a fall in material costs results in a benefit to operating
results. For example, in 2007, the effect of falling raw material costs on our LIFO inventory
valuation method resulted in cost of sales which was $92.1 million lower than have been recognized
had we utilized the FIFO methodology to value our inventory. However, in 2006 and 2005, the effect
of increases in raw material costs on our LIFO inventory valuation method resulted in cost of sales
which were $197.0 million, and $45.8 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.
The LIFO inventory valuation methodology is not utilized by many of the companies with which
we compete, including foreign competitors. As such, our results of operations may not be
comparable to those of our competitors during periods of volatile material costs due, in part, to
the differences between the LIFO inventory valuation method and other acceptable inventory
valuation methods.
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, 2007, 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.
Retirement Benefits
We have defined benefit and defined contribution pension plans covering substantially all of our
employees. 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
43
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 has been 8.75% for each of past five years. 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 10.9% for 2007, 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 five years, our expected return on pension
plan investments for 2008 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 $6.0 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, we determined 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 2007, we established a discount rate of 6.25% for valuing the pension
liabilities as of the end of 2007, and for determining the pension expense for 2008. We had
previously assumed a discount rate of 5.8% for 2006, which determined the 2007 expense, 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 increasing the discount rate to 6.25%,
from 5.8% in the previous year, decreased pension liabilities by approximately $103 million at 2007
year-end, and is expected to decrease pension expense by approximately $8.1 million in 2008. 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 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 was not restated. In addition, the new standard requires 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 in our measurement date is
effective for our year ending December 31, 2008.
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 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 at year-end 2006. These charges and adjustments did not affect our results
of operations and did not have a cash impact.
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
44
capped based upon the cost as of certain dates, 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 FAS No. 106, Employers Accounting for
Postretirement Benefits Other Than Pensions (FAS 106), as amended by FAS 158, 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 each year, is developed based upon rates of return
on high quality, fixed-income investments. At the end of 2007, we determined this rate to be 6.25%,
compared to a 5.8% discount rate in 2007, 5.9% discount rate in 2005, 6.1% discount rate in 2004
and 6.5% in 2003. The effect of increasing the discount rate to 6.25% from 5.8% reduced year-end
2007 postretirement benefit liabilities by approximately $18.0 million and is expected to decrease
2008 expense by approximately $0.6 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 10.8% for 2008 and is assumed to gradually decrease to
5.0% in the year 2019 and remain level thereafter.
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
2007, 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 16.9% in 2007, 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 2008. 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.
New Accounting Pronouncements Adopted
In the 2007 first quarter, as required, we adopted Financial Accounting Standards Board (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 was the policy we previously
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 was effective as of the beginning of our 2007 fiscal year, with retrospective application to
all prior periods presented. Under the FSP PMMA, we report results using the deferral method
whereby major equipment rebuilds are capitalized as costs are incurred and amortized to expense
over the 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 $10.3 million, net of related taxes. As required by the FSP PMMA, our
financial statements have been restated to reflect this FSP as if this standard had been applied to
the earliest period presented. As a result, our net income for 2006, 2005 and 2004 increased $2.2
million, $2.6 million and $1.6 million, respectively, or approximately $0.02 per share for each
year.
In the 2007 first quarter, we also adopted 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, the benefit of 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 of $5.6 million as of the beginning of 2007.
As a result of implementing FIN 48, we recognized a $19.4 million increase in the long-term
liability for unrecognized tax benefits, and a $13.8 million increase in deferred tax assets for
tax positions for which the ultimate deductibility is highly certain, but for which there is
uncertainty about the timing of such deductibility. Because of the impact of deferred tax
accounting, other than interest and penalties, the disallowance of the shorter deductibility period
would not affect the annual effective tax rate but would accelerate the payment of cash to the
taxing authority to an earlier period. The net result of these recognized assets and liabilities
was
45
a reduction to beginning retained earnings of $5.6 million. Including liabilities recognized
in the FIN 48 adoption, our total liabilities for unrecognized tax benefits at January 1, 2007 were
$26.3 million. Interest and penalties recognized at the FIN 48 adoption were $3.5 million. It is
our policy to classify interest and penalties recognized on underpayment of income taxes as income
tax expense. For the year ended December 31, 2007, the Companys income tax provision included
$11.8 million of expense related to uncertain tax positions, which increased the long-term
liability to $38.1 million. We expect that settlements for nearly all of the contractual cash
obligations for liabilities for uncertain tax positions will occur more than five years in the
future.
Including tax positions for which we determined that the tax position would not meet the
more-likely-than-not recognition threshold upon examination by the tax authorities based upon the
technical merits of the position, the total estimated unrecognized tax benefit that, if recognized,
would affect our effective tax rate was approximately $20 million. At this time, we believe that
it is reasonably possible that approximately $2 million of the estimated unrecognized tax benefits
as of December 31, 2007 will be recognized within the next twelve months.
In September 2006, the FASB Statement No. 158 (FAS 158), was issued amending the 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 difference between plan
assets and 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 was recognized 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 our 2008 year.
In the fourth quarter 2005, we adopted the FASB Interpretation No. 47, Accounting for
Conditional Asset Retirement Obligations (FIN 47), an interpretation of FASB Statement No. 143,
Accounting for Asset Retirement Obligations (FAS 143). FIN 47 clarifies that the term
conditional asset retirement obligation as used in FAS 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.
Pending Accounting Pronouncements
In September 2006, the FASB issued FAS 157, Fair Value Measurements. This Standard defines
fair value, establishes a framework for measuring fair value and expands disclosures about fair
value measurements. This statement applies under other accounting pronouncements that require or
permit fair value measurements, but does not require any new fair value measurements. The Standard
covers financial assets and liabilities, as well as for any other assets and liabilities that are
carried at fair value on a recurring basis in financial statements. FAS 157 is effective for
fiscal years beginning after November 15, 2007 for financial assets and liabilities, and for fiscal
years beginning after November 15, 2008 for other nonfinancial assets and liabilities. The Company
does not expect that the adoption of FAS 157 will have a material impact on our financial
statements.
In February 2007, the FASB issued Statement of Financial Accounting Standards No. 159 (FAS
159), The Fair Value Option for Financial Assets and Liabilities. FAS 159 permits entities to
choose to measure many financial instruments and certain other items at fair value. If the fair
value option is elected, unrealized gains and losses will be recognized in earnings at each
subsequent reporting date. FAS 159 is effective for fiscal years beginning after November 15, 2007.
We are currently evaluating the impact of adopting FAS 159 but do not expect the adoption to have a
material impact on our financial statements.
In December 2007, the FASB issued Statement of Financial Accounting Standards No. 160 (FAS
160), Noncontrolling Interests in Consolidated Financial Statements. FAS 160 changes the
classification of noncontrolling (minority) interests on the balance sheet and the accounting for
and reporting of transactions between the reporting entity and holders of such noncontrolling
46
interests. Under the new standard, noncontrolling interests are considered equity and are to
be reported as an element of stockholders equity rather than within the mezzanine or liability
sections of the balance sheet. In addition, the current practice of reporting minority interest
expense or benefit also will change. Under the new standard, net income will encompass the total
income before minority interest expense. The income statement will include separate disclosure of
the attribution of income between the controlling and noncontrolling interests. Increases and
decreases in the noncontrolling ownership interest amount are to accounted for as equity
transactions. FAS 160 is effective for fiscal years beginning after December 15, 2008 and earlier
application is prohibited. Upon adoption, the balance sheet and the income statement will be recast
retrospectively for the presentation of noncontrolling interests. The other accounting provisions
of the statement are required to be adopted prospectively. We are currently evaluating the impact
of adopting FAS 160, including the reporting of the minority interest in our STAL joint venture,
will have on our financial statements. As of December 31, 2007, other long-term liabilities
included $55.7 million for minority interest in our STAL joint venture.
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.
47
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, 2007, we had approximately $59
million of floating rate debt outstanding with a weighted average interest rate of approximately
4.7%. Approximately $41 million of this floating rate debt is capped at a 6% maximum interest 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 $18 million of our outstanding floating rate debt not subjected to a cap would
result in increased annual financing costs of approximately $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, in
2007 we used approximately 80 million pounds of nickel; therefore a hypothetical change of $1.00
per pound in nickel prices would result in increased costs of approximately $80 million. In
addition, in 2007 we also used approximately 500 million pounds of ferrous scrap in the production
of our flat-rolled products and a hypothetical change of $0.01 per pound would result in increased costs of
approximately $5 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.
48
Item 8. Financial Statements and Supplementary Data
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, 2007 and 2006, and the related consolidated statements of
income, stockholders equity, and cash flows for each of the three years in the period ended
December 31, 2007. 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, 2007 and 2006, and the consolidated results of their operations and
their cash flows for each of the three years in the period ended December 31, 2007, in conformity
with U.S. generally accepted accounting principles.
As described in Note 7 to the financial statements, the Company changed its accounting for
income tax uncertainties in 2007. As described in Note 8 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, 2007, 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, 2008 expressed an unqualified opinion
thereon.
/s/ Ernst & Young LLP
Pittsburgh, Pennsylvania
February 21, 2008
49
Allegheny Technologies Incorporated and Subsidiaries
Consolidated Statements of Income
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(In millions except per share amounts)
|
|
|
|
|
|
|
|
|
|
|
For the Years Ended December 31,
|
|
2007
|
|
|
2006
|
|
|
2005
|
|
|
|
|
Sales
|
|
$
|
5,452.5
|
|
|
$
|
4,936.6
|
|
|
$
|
3,539.9
|
|
|
|
|
Costs and expenses:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Cost of sales
|
|
|
4,003.1
|
|
|
|
3,740.4
|
|
|
|
2,885.7
|
|
|
Selling and administrative expenses
|
|
|
296.7
|
|
|
|
295.3
|
|
|
|
275.8
|
|
|
Restructuring costs
|
|
|
|
|
|
|
|
|
|
|
23.9
|
|
|
|
|
Income before interest, other expense, income taxes and cumulative effect of change in
accounting principle
|
|
|
1,152.7
|
|
|
|
900.9
|
|
|
|
354.5
|
|
|
Interest expense, net
|
|
|
(4.8
|
)
|
|
|
(23.3
|
)
|
|
|
(38.6
|
)
|
|
Other expense, net
|
|
|
(0.6
|
)
|
|
|
(5.0
|
)
|
|
|
(4.8
|
)
|
|
|
|
Income before income taxes and cumulative effect of change in accounting principle
|
|
|
1,147.3
|
|
|
|
872.6
|
|
|
|
311.1
|
|
|
Income tax provision (benefit)
|
|
|
400.2
|
|
|
|
298.5
|
|
|
|
(53.3
|
)
|
|
|
|
Income before cumulative effect of change in accounting principle
|
|
|
747.1
|
|
|
|
574.1
|
|
|
|
364.4
|
|
|
Cumulative effect of change in accounting principle, net of tax
|
|
|
|
|
|
|
|
|
|
|
(2.0
|
)
|
|
|
|
Net income
|
|
$
|
747.1
|
|
|
$
|
574.1
|
|
|
$
|
362.4
|
|
|
|
|
Basic income per common share before cumulative effect of change in accounting principle
|
|
$
|
7.35
|
|
|
$
|
5.76
|
|
|
$
|
3.79
|
|
|
Cumulative effect of change in accounting principle
|
|
|
|
|
|
|
|
|
|
|
(0.02
|
)
|
|
|
|
Basic net income per common share
|
|
$
|
7.35
|
|
|
$
|
5.76
|
|
|
$
|
3.77
|
|
|
|
|
|
|
Diluted income per common share before cumulative effect of change in accounting principle
|
|
$
|
7.26
|
|
|
$
|
5.61
|
|
|
$
|
3.61
|
|
|
Cumulative effect of change in accounting principle
|
|
|
|
|
|
|
|
|
|
|
(0.02
|
)
|
|
|
|
Diluted net income per common share
|
|
$
|
7.26
|
|
|
$
|
5.61
|
|
|
$
|
3.59
|
|
|
|
The accompanying notes are an integral part of these statements.
50
Allegheny Technologies Incorporated and Subsidiaries
Consolidated Balance Sheets
|
|
|
|
|
|
|
|
|
|
|
|
|
December 31,
|
|
|
December 31,
|
|
|
(In millions except share and per share amounts)
|
|
2007
|
|
|
2006
|
|
|
|
|
Assets
|
|
|
|
|
|
|
|
|
|
Cash and cash equivalents
|
|
$
|
623.3
|
|
|
$
|
502.3
|
|
|
Accounts receivable, net
|
|
|
652.2
|
|
|
|
610.9
|
|
|
Inventories, net
|
|
|
916.1
|
|
|
|
798.7
|
|
|
Deferred income taxes
|
|
|
18.8
|
|
|
|
26.6
|
|
|
Prepaid expenses and other current assets
|
|
|
38.3
|
|
|
|
49.4
|
|
|
|
|
Total Current Assets
|
|
|
2,248.7
|
|
|
|
1,987.9
|
|
|
Property, plant and equipment, net
|
|
|
1,239.5
|
|
|
|
871.7
|
|
|
Prepaid pension asset
|
|
|
230.3
|
|
|
|
|
|
|
Cost in excess of net assets acquired
|
|
|
209.8
|
|
|
|
206.5
|
|
|
Deferred income taxes
|
|
|
42.1
|
|
|
|
119.0
|
|
|
Other assets
|
|
|
125.2
|
|
|
|
95.4
|
|
|
|
|
Total Assets
|
|
$
|
4,095.6
|
|
|
$
|
3,280.5
|
|
|
|
|
Liabilities and Stockholders Equity
|
|
|
|
|
|
|
|
|
|
Accounts payable
|
|
$
|
388.4
|
|
|
$
|
355.1
|
|
|
Accrued liabilities
|
|
|
294.7
|
|
|
|
264.3
|
|
|
Short-term debt and current portion of long-term debt
|
|
|
20.9
|
|
|
|
23.7
|
|
|
|
|
Total Current Liabilities
|
|
|
704.0
|
|
|
|
643.1
|
|
|
Long-term debt
|
|
|
507.3
|
|
|
|
529.9
|
|
|
Retirement benefits
|
|
|
469.6
|
|
|
|
464.4
|
|
|
Other long-term liabilities
|
|
|
191.2
|
|
|
|
140.2
|
|
|
|
|
Total Liabilities
|
|
|
1,872.1
|
|
|
|
1,777.6
|
|
|
|
|
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
102,404,256 at 2007 and 101,201,411 at 2006; outstanding 101,586,334 shares
at 2007 and 101,201,328 shares at 2006
|
|
|
10.2
|
|
|
|
10.1
|
|
|
Additional paid-in capital
|
|
|
693.7
|
|
|
|
637.0
|
|
|
Retained earnings
|
|
|
1,830.7
|
|
|
|
1,166.6
|
|
|
Treasury stock: 817,922 shares at 2007 and 83 shares at 2006
|
|
|
(75.4
|
)
|
|
|
|
|
|
Accumulated other comprehensive loss, net of tax
|
|
|
(235.7
|
)
|
|
|
(310.8
|
)
|
|
|
|
Total Stockholders Equity
|
|
|
2,223.5
|
|
|
|
1,502.9
|
|
|
|
|
Total Liabilities and Stockholders Equity
|
|
$
|
4,095.6
|
|
|
$
|
3,280.5
|
|
|
|
The accompanying notes are an integral part of these statements.
51
Allegheny Technologies Incorporated and Subsidiaries
Consolidated Statements of Cash Flows
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(In millions)
|
|
|
|
|
|
|
|
|
|
|
For the Years Ended December 31,
|
|
2007
|
|
|
2006
|
|
|
2005
|
|
|
|
|
Operating Activities:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net income
|
|
$
|
747.1
|
|
|
$
|
574.1
|
|
|
$
|
362.4
|
|
|
Adjustments to reconcile net income to net cash provided by operating activities:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Depreciation and amortization
|
|
|
102.9
|
|
|
|
86.2
|
|
|
|
78.5
|
|
|
Deferred income taxes
|
|
|
55.5
|
|
|
|
9.4
|
|
|
|
(90.6
|
)
|
|
Non-cash restructuring costs
|
|
|
|
|
|
|
|
|
|
|
22.4
|
|
|
Cumulative effect of change in accounting principle
|
|
|
|
|
|
|
|
|
|
|
2.0
|
|
|
Change in operating assets and liabilities:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Inventories
|
|
|
(117.4
|
)
|
|
|
(191.6
|
)
|
|
|
(87.9
|
)
|
|
Retirement benefits (a)
|
|
|
(102.4
|
)
|
|
|
(49.6
|
)
|
|
|
(53.4
|
)
|
|
Accrued liabilities
|
|
|
56.6
|
|
|
|
30.7
|
|
|
|
38.7
|
|
|
Accounts receivable
|
|
|
(41.3
|
)
|
|
|
(168.8
|
)
|
|
|
(78.7
|
)
|
|
Accounts payable
|
|
|
33.3
|
|
|
|
42.2
|
|
|
|
39.0
|
|
|
Accrued income taxes, net of tax benefit on share-based compensation
|
|
|
(5.3
|
)
|
|
|
4.2
|
|
|
|
18.5
|
|
|
Other
|
|
|
(19.2
|
)
|
|
|
(25.2
|
)
|
|
|
(27.1
|
)
|
|
|
|
Cash provided by operating activities
|
|
|
709.8
|
|
|
|
311.6
|
|
|
|
223.8
|
|
|
|
|
Investing Activities:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Purchases of property, plant and equipment
|
|
|
(447.4
|
)
|
|
|
(238.3
|
)
|
|
|
(91.3
|
)
|
|
Purchase of businesses and investments in ventures, net of cash acquired
|
|
|
(9.7
|
)
|
|
|
|
|
|
|
(18.3
|
)
|
|
Disposals of property, plant and equipment
|
|
|
4.7
|
|
|
|
2.0
|
|
|
|
0.6
|
|
|
Proceeds from sales of businesses and investments and other
|
|
|
0.7
|
|
|
|
0.5
|
|
|
|
(1.4
|
)
|
|
|
|
Cash used in investing activities
|
|
|
(451.7
|
)
|
|
|
(235.8
|
)
|
|
|
(110.4
|
)
|
|
|
|
Financing Activities:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Payments of long-term debt and capital leases
|
|
|
(15.3
|
)
|
|
|
(7.8
|
)
|
|
|
(38.5
|
)
|
|
Borrowings of long-term debt
|
|
|
|
|
|
|
|
|
|
|
11.0
|
|
|
Net borrowings (repayments) under credit facilities
|
|
|
(8.6
|
)
|
|
|
0.7
|
|
|
|
1.8
|
|
|
|
|
Net repayments
|
|
|
(23.9
|
)
|
|
|
(7.1
|
)
|
|
|
(25.7
|
)
|
|
Purchase of treasury stock
|
|
|
(61.2
|
)
|
|
|
|
|
|
|
|
|
|
Dividends paid
|
|
|
(58.1
|
)
|
|
|
(43.1
|
)
|
|
|
(27.1
|
)
|
|
Tax benefit on share-based compensation
|
|
|
50.7
|
|
|
|
80.9
|
|
|
|
25.2
|
|
|
Income tax withholding on share-based compensation
|
|
|
(50.1
|
)
|
|
|
|
|
|
|
|
|
|
Exercises of stock options
|
|
|
5.5
|
|
|
|
33.1
|
|
|
|
26.1
|
|
|
|
|
Cash provided by (used in) financing activities
|
|
|
(137.1
|
)
|
|
|
63.8
|
|
|
|
(1.5
|
)
|
|
|
|
Increase in cash and cash equivalents
|
|
|
121.0
|
|
|
|
139.6
|
|
|
|
111.9
|
|
|
Cash and cash equivalents at beginning of year
|
|
|
502.3
|
|
|
|
362.7
|
|
|
|
250.8
|
|
|
|
|
Cash and cash equivalents at end of year
|
|
$
|
623.3
|
|
|
$
|
502.3
|
|
|
$
|
362.7
|
|
|
|
|
|
|
|
|
(a)
|
|
Includes annual voluntary cash pension contributions of $(100.0) million in 2007, 2006 and 2005.
|
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.
52
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, 2004
|
|
$
|
9.9
|
|
|
$
|
481.2
|
|
|
$
|
351.0
|
|
|
$
|
(79.4
|
)
|
|
$
|
(331.3
|
)
|
|
$
|
431.4
|
|
|
|
|
Net income
|
|
|
|
|
|
|
|
|
|
|
362.4
|
|
|
|
|
|
|
|
|
|
|
|
362.4
|
|
|
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
|
|
|
|
|
|
|
|
|
|
|
362.4
|
|
|
|
|
|
|
|
(38.1
|
)
|
|
|
324.3
|
|
|
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
|
|
|
|
650.7
|
|
|
|
(18.8
|
)
|
|
|
(369.4
|
)
|
|
|
808.0
|
|
|
|
|
Net income
|
|
|
|
|
|
|
|
|
|
|
574.1
|
|
|
|
|
|
|
|
|
|
|
|
574.1
|
|
|
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
|
|
|
|
|
|
|
|
|
|
|
574.1
|
|
|
|
|
|
|
|
401.2
|
|
|
|
975.3
|
|
|
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
|
|
|