THE INFORMATION IN THIS PRELIMINARY PROSPECTUS SUPPLEMENT IS NOT COMPLETE AND MAY BE CHANGED. THIS PRELIMINARY PROSPECTUS SUPPLEMENT AND THE ACCOMPANYING PROSPECTUS ARE NOT AN OFFER TO SELL THESE SECURITIES, AND WE ARE NOT SOLICITING AN OFFER TO BUY THESE SECURITIES IN ANY JURISDICTION WHERE THE OFFER OR SALE IS NOT PERMITTED.
SUBJECT TO COMPLETION, DATED JULY 12, 2004
PRELIMINARY PROSPECTUS SUPPLEMENT
(TO PROSPECTUS DATED MAY 26, 2004)
10,000,000 SHARES
[ALLEGHENY TECHNOLOGIES INCORPORATED LOGO]
COMMON STOCK
Allegheny Technologies Incorporated is offering 10,000,000 shares of common stock.
Our common stock is listed on the New York Stock Exchange under the symbol "ATI." On July 9, 2004, the last reported sale price of our common stock as reported by the New York Stock Exchange was $17.80 per share.
INVESTING IN OUR COMMON STOCK INVOLVES RISKS. SEE "RISK FACTORS"
BEGINNING ON PAGE S-6 OF THIS PROSPECTUS SUPPLEMENT AND PAGE 2 OF THE ACCOMPANYING
PROSPECTUS.
PER
SHARE TOTAL
--------- ------------
Public offering price $ $
Underwriting discounts $ $
Proceeds to Allegheny Technologies Incorporated, before
expenses $ $
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NEITHER THE SECURITIES AND EXCHANGE COMMISSION NOR ANY STATE SECURITIES COMMISSION HAS APPROVED OR DISAPPROVED OF THESE SECURITIES OR PASSED UPON THE ADEQUACY OR ACCURACY OF THIS PROSPECTUS SUPPLEMENT OR THE ACCOMPANYING PROSPECTUS. ANY REPRESENTATION TO THE CONTRARY IS A CRIMINAL OFFENSE.
The underwriters expect to deliver the shares of common stock to investors on or about , 2004.
JPMORGAN CITIGROUP
Co-Managers
BANC OF AMERICA SECURITIES LLC MERRILL LYNCH & CO.
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PAGE
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Prospectus Supplement Summary............................... S-1
Risk Factors................................................ S-6
Forward-Looking Statements.................................. S-9
Use of Proceeds............................................. S-10
Price Range of Our Common Stock and Dividend Policy......... S-11
Capitalization.............................................. S-12
Selected Consolidated Financial Data........................ S-13
Management's Discussion and Analysis of Financial Condition
and Results of Operations................................. S-14
Underwriting................................................ S-31
Legal Matters............................................... S-34
Independent Registered Public Accounting Firm............... S-34
Where You Can Find More Information......................... S-34
PROSPECTUS
Where You Can Find More Information......................... ii
Summary..................................................... 1
Risk Factors................................................ 2
Forward-Looking Statements.................................. 9
Ratios of Earnings To Fixed Charges......................... 9
Use of Proceeds............................................. 9
Description of Capital Securities........................... 10
Description of Warrants..................................... 14
Description of Depositary Shares............................ 15
Description of Purchase Contracts........................... 18
Description of Purchase Units............................... 18
Description of Debt Securities.............................. 19
Plan of Distribution........................................ 28
Legal Matters............................................... 30
Experts..................................................... 30
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You should rely only on the information contained or incorporated by reference in this prospectus supplement and the accompanying prospectus. We have not authorized anyone to provide you with different information. We are not making an offer to sell these securities in any state where the offer is not permitted. You should not assume that the information contained or incorporated by reference in this prospectus supplement or the prospectus is accurate as of any date other than the dates on the front covers of these documents.
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.
The following information supplements, and should be read together with, the information contained or incorporated by reference in other parts of this prospectus supplement and in the accompanying prospectus. This summary highlights selected information contained elsewhere in this prospectus supplement, the accompanying prospectus and the documents incorporated by reference to help you understand our business. Because the following is only a summary, it does not contain all of the information that may be important to you. You should carefully read this prospectus supplement, the accompanying prospectus and the documents incorporated by reference before deciding whether to invest in our common stock. You should pay special attention to "Risk Factors" beginning on page S-6 of this prospectus supplement and beginning on page 2 of the accompanying prospectus to determine whether an investment in our common stock is appropriate for you.
ALLEGHENY TECHNOLOGIES INCORPORATED
We believe that we are one of the largest and most diversified specialty materials producers in the world. We use innovative technologies to offer global markets a wide range of specialty materials. Our high-value products include super stainless steel, nickel- and cobalt-based alloys and superalloys, titanium and titanium alloys, specialty steels, tungsten materials, exotic alloys, such as zirconium, hafnium and niobium, and highly engineered strip and Precision Rolled Strip(R) products. In addition, we produce commodity specialty materials such as stainless steel sheet and plate, silicon electrical and tool steels, and carbon alloy steel impression die forgings and large grey and ductile iron castings. Our high-value products accounted for 68% of total revenues in 2003, and our commodity products accounted for 32% of total revenues in 2003.
We operate in the following three business segments, which accounted for the following percentages of our total revenues of $2.13 billion, $1.91 billion, and $1.94 billion for the years ended December 31, 2001, 2002 and 2003, respectively:
YEAR ENDED
DECEMBER 31,
------------------
2001 2002 2003
---- ---- ----
Flat-Rolled Products........................................ 51% 55% 54%
High Performance Metals..................................... 36% 33% 33%
Engineered Products......................................... 13% 12% 13%
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Our specialty materials are produced in a variety of alloys and forms, and are selected for use in environments that demand materials having exceptional hardness, toughness, strength, resistance to heat, corrosion or abrasion, or a combination of these characteristics. Common end markets of our products include the aerospace, electrical energy, automotive, chemical processing, oil and gas, construction and mining, machine and cutting tool, appliance and food equipment, transportation and medical industries.
ACQUISITION OF J&L SPECIALTY STEEL ASSETS AND NEW LABOR AGREEMENT
On June 1, 2004, our Allegheny Ludlum operation, the largest business in our Flat-Rolled Products segment, completed the acquisition of substantially all of the assets of J&L Specialty Steel, LLC, a producer of flat-rolled stainless steel products with operations in Midland, Pennsylvania and Louisville, Ohio, for approximately $67 million in total consideration and the assumption of certain current liabilities. The purchase price is subject to final audit adjustment and is payable over several years. We believe that the acquisition of the J&L Specialty Steel assets is consistent with our business strategy to transform our stainless steel business into a highly efficient, cost competitive operation.
- Strengthen our overall position in the domestic stainless steel
market. With the addition of the J&L Specialty Steel assets we believe
that we have become the largest domestic producer of flat-rolled
stainless steel products, as measured by stainless steel making capacity.
We estimate that our Allegheny Ludlum operation will be capable of annual
shipments in excess of 700,000 tons of flat-rolled specialty metals with
approximately 2,650 production and maintenance employees. By comparison,
Allegheny Ludlum shipped 478,000 tons of these metals in 2003 with over
3,000 production and maintenance employees.
- Generate significant cost savings. The acquisition of the J&L Specialty Steel assets and the negotiation of the new labor agreement with the USWA are expected to improve the performance of our Allegheny Ludlum business. We expect the new labor agreement, combined with the integration of the J&L operations, to generate annual cost structure improvements of approximately $200 million when workforce restructuring and synergies are fully implemented in the second half of 2006. We anticipate these cost structure improvements to come from reduced labor costs, operating synergies, improved product mix, and reduced fixed costs. In the aggregate, we expect these initiatives to result in a competitive cost structure for our stainless steel business.
COMPETITIVE STRENGTHS
Leading Diversified Special Metals Company. We believe that our increased size and market position will enable us to more effectively serve the needs of customers, lower our cost structure through economies of scale, and position us to profitably grow our businesses. After giving effect to the recently completed purchase of the J&L Specialty Steel assets, we believe that we are the largest domestic producer of flat-rolled stainless steel, as measured by stainless steel making capacity. We also enjoy leadership positions in markets for many of the other specialty metals that we produce and have one of the most diversified product offerings in the specialty metals industry. Common end markets for our products include the aerospace, electrical energy, automotive, chemical processing, oil and gas, construction and mining, machine and cutting tool, appliance and food equipment, transportation and medical industries.
Lower Operating Cost Structure. During the past several years of the U.S. manufacturing industry's downturn, we have been successful in improving our cost structure, decreasing our managed working capital relative to sales, streamlining processes and improving productivity. We have also invested in our operating facilities to enhance our capabilities and to increase production efficiencies and competitiveness. As a result of these initiatives, in 2003 we achieved $117 million in gross cost reductions, before the effects of inflation, exceeding our initial 2003 goal of $90 million. With the recent acquisition of the J&L Specialty Steel assets and the new labor agreement with the USWA, we believe that we should become one of the lowest cost producers in the North American stainless steel industry.
Technological Leadership. We have maintained our commitment to technological leadership in the specialty metals industry, and regularly introduce new alloys to better serve our customers. Among the new alloys introduced in 2003 were: 718 Plus(TM) alloy, a nickel-based superalloy that is a cost effective new alternative to meet the demanding needs of next generation jet engines; ATI(TM) 425 titanium, an innovative new patented titanium alloy that is a cost effective alternative to the most commonly used high-strength titanium alloy; and AL 2003(TM) alloy, a new patented stainless steel duplex alloy that is an economic alternative to higher nickel-based stainless steels and duplex alloys.
Strong Customer Relationships. We focus on providing high quality products to our customers, which we believe has led to longstanding customer relationships. We believe that we have an unsurpassed reputation with our customers for providing high quality products and customer service, as well as for timely delivery.
Experienced, Committed Management Team. Our business is managed by an experienced team of executive officers, led by Pat Hassey, our Chairman, President and Chief Executive Officer. Our management team includes many other experienced officers in key functional areas, including operations, sales, marketing, accounting, finance, and legal. Our executive officers and other members of our management team are committed to growing our business, reducing costs, and pursuing other initiatives to deliver sustained earnings growth and higher value to our stockholders.
BUSINESS STRATEGY
Capitalize on Beginning of Cyclical Recoveries of End Markets. We believe that general economic conditions are improving and that demand for products of our Flat-Rolled Products segment has improved significantly. As a result, we have taken several price restoration actions with respect to these products in 2004. We believe that these improved market conditions, together with our lower cost structure, should result in improved financial performance by our Flat-Rolled Products segment.
We have experienced some strengthening of demand for our High Performance Metals products, including nickel-based alloys and titanium. Many industry analysts are forecasting a recovery for the commercial aerospace industry, a key end-market for this segment's products, within the next two years. As the market for these products improves, the recently completed enhancements to our Richburg, South Carolina long products rolling mill, as well as other investments, should enable us to enhance our market position for our nickel-based superalloy, titanium alloy and specialty steel product lines.
Continue Our Focus on Cost Reduction. We are targeting additional gross cost reductions of $104 million in 2004. In addition, we anticipate annual cost structure improvements of approximately $200 million when workforce restructuring and synergies from the J&L Specialty Steel assets acquisition and our new labor agreement are fully implemented in the second half of 2006.
Enhance Our Financial Flexibility. We have maintained adequate liquidity from cash generated from operations notwithstanding depressed market conditions for many of our products, and the incurrence of losses, during the past three years. We also have not yet drawn any amounts under our secured revolving credit facility, which has to date been used to support letters of credit. The net proceeds from this offering will further enhance our financial flexibility, enabling us to pursue investments and opportunities that offer attractive returns, and to reduce our outstanding liabilities, including through voluntary contributions to our defined benefit pension trust or by the repayment or repurchase of long-term debt.
Grow Our Global Business Platform. Approximately 25% of our sales came from outside the United States in 2003. In the future, we plan to expand our international presence through the utilization of our international assets and the pursuit of strategic opportunities that are consistent with our business strategy. Examples of our successful international alliances include Shanghai STAL Precision Stainless Steel Company Limited (STAL), our Precision Rolled Strip(R) products joint venture in China, and Uniti LLC, a U.S.-based industrial titanium joint venture with a Russian producer of titanium, aluminum and specialty steel products.
Expand Our Exotic Alloys Business. Our exotic alloys business, Wah Chang, has benefited from sustained high demand for its products from the high-energy physics and government markets, as well as corrosion markets in Asia. We plan to continue to be a premier supplier of these products to the U.S. government and to meet the growing demand from the corrosion, medical imaging and biomedical markets. We intend to continue to grow our exotic alloys business through investments focused on capacity expansion and cost reduction.
COMMENTS ON SECOND QUARTER 2004
On June 28, 2004, we issued a press release that stated that we expected second quarter 2004 operating results to be favorably impacted by improving market conditions and special items. Specifically, we stated that we expect our Flat-Rolled Products segment to record positive operating profit in the second quarter 2004, which would be the first quarterly operating profit from Allegheny Ludlum since the 2002 third quarter. We are experiencing increased demand for our flat-rolled products, and we have taken several price restoration actions in 2004.
Also in the second quarter 2004, special items are expected to result in a one-time gain of approximately $39 million, or $0.48 per share, due to the following:
- A $71 million curtailment and settlement gain as a result of actions taken to cap, beginning in 2005, and then eliminate, beginning in 2010, certain retiree medical benefits not related to Allegheny Ludlum's new labor agreement;
- A $25 million charge resulting from transition incentives as provided in our new labor agreement. The transition incentives will be paid from our pension fund over the next two and a half years to 650 Allegheny Ludlum employees who decide to retire by 2006; and
- A $7 million charge as a result of other costs associated with our new labor agreement and the acquisition of the J&L Specialty Steel assets.
As a result of actions taken during the second quarter 2004, we have reduced our liability for Other Postretirement Benefits (OPEB) by approximately $285 million, or 31%. This improvement is primarily the result of actions resulting in the curtailment and settlement gain discussed above and from the impact of the retiree medical benefit cost cap in the new labor agreement. We currently expect these actions to reduce our annual retirement benefit expense (pension expense and OPEB expense) by approximately $40 million for 2005, based upon current actuarial assumptions. While results for the second quarter 2004 will be slightly impacted by this change, we expect retirement benefit expense for the third and fourth quarters 2004 to be reduced by approximately $9.4 million in each quarter to $26.6 million from $36.0 million.
Our principal offices are located at 1000 Six PPG Place, Pittsburgh, Pennsylvania 15222. Our telephone number is (412) 394-2800. Our website address is www.alleghenytechnologies.com. Information contained on our website is not part of, and should not be construed as being incorporated by reference into, this prospectus supplement or the accompanying prospectus.
Precision Rolled Strip(R), 718 Plus(TM), ATI(TM), AL 2003(TM) and our corporate logos included in this prospectus supplement are trademarks of Allegheny Technologies Incorporated and its subsidiaries in the United States and other countries. All other trademarks or service marks are trademarks or service marks of the companies that use them.
Common stock offered by
Allegheny Technologies
Incorporated.................. 10,000,000 shares
Common stock to be outstanding
after this offering........... 91,381,624 shares
Overallotment option.......... 1,500,000 shares
Use of proceeds............... We intend to use a portion of the net proceeds
from this offering to enhance our abilities to
make growth-oriented investments, including
capital investments and acquisitions that we
believe will offer attractive returns. We also
intend to use a portion of the net proceeds to
strengthen our balance sheet by reducing our
outstanding liabilities, which may include
making voluntary contributions to our defined
benefit pension trust or the repayment or
repurchase of our long-term debt securities. We
may also use a portion of the net proceeds for
other general corporate purposes.
New York Stock Exchange
symbol........................ ATI
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The number of shares of our common stock to be outstanding after this offering is based on 81,381,624 shares outstanding as of June 30, 2004. The number of shares of our common stock that will be outstanding after the offering excludes:
- an aggregate of 6,516,990 shares of common stock reserved for issuance upon exercise of outstanding options, at a weighted average exercise price of $11.88 per share; and
- an aggregate of 4,532,951 additional shares of common stock available for future issuance under our incentive compensation plans.
Unless otherwise noted, the information in this prospectus supplement assumes that the underwriters' overallotment option will not be exercised.
An investment in our common stock involves risks. You should carefully consider the risks described below and other information in this prospectus supplement and the accompanying prospectus, including the financial information contained in "Management's Discussion and Analysis of Financial Condition and Results of Operations" and our consolidated financial statements and the related notes included elsewhere or incorporated by reference in this prospectus supplement, before making an investment decision. The risks and uncertainties described below and in the accompanying prospectus are not the only ones we face. Additional risks and uncertainties not presently known to us or that we currently deem immaterial may also impair our business operations. If any of the following risks actually occur, our business, financial condition or results of operations could be materially adversely affected. This could cause a decline in the trading price of our common stock, and you may lose all or part of your investment.
RISKS RELATING TO OUR BUSINESS
In addition to the risk described below, our business is subject to a number of risks related to our industry generally and our business specifically. See also "Risk Factors" included on pages 2 through 8 of the accompanying prospectus.
We expect to achieve significant cost savings and other benefits from our recent acquisition of the J&L Specialty Steel assets and the new labor contract we entered into with respect to our Allegheny Ludlum operation. While we have achieved some of these savings and benefits already, there can be no assurance that we will achieve any or all of the anticipated balance, or that the savings we are able to achieve can be sustained over the long term.
In the event we are unable to successfully implement any of our planned cost savings or business initiatives, or are unable to sustain any that we do successfully implement, we may not realize all of the benefits we currently anticipate from the J&L Specialty Steel asset acquisition and the new labor contract, and our results of operations could suffer as a result.
RISKS RELATING TO THIS OFFERING
OUR COMMON STOCK PRICE COULD BE VOLATILE DUE TO THE NATURE OF OUR BUSINESS AS WELL AS THE NATURE OF THE SECURITIES MARKETS, WHICH COULD AFFECT THE SHORT-TERM VALUE OF YOUR INVESTMENT.
Our common stock is quoted on the New York Stock Exchange. From January 1, 2003 to July 9, 2004, the sales price per share of our common stock as reported by the New York Stock Exchange ranged from a low of $2.10 to a high of $18.40. We believe that, among other factors, including factors relating to our operating performance, any of the following factors could cause the price of our common stock to fluctuate substantially:
- changes in length of sales cycles of or demand by our customers for existing and additional products;
- changes in our pricing policies or those of our competitors or suppliers;
- changes in our mix of sources of revenue;
- introduction of new products by us or our competitors;
- the trading volume of our common stock in the public market;
- general economic conditions;
- changes in raw material and energy costs and availability;
- issues associated with suppliers of raw materials, third party converters or other business service providers;
- financial market conditions;
- acts of terrorism; and
- threats of war and other force majeure conditions.
While we have historically paid cash dividends on our common stock, we cannot assure you that in the future we will not reduce the amount of dividends paid, or stop paying dividends at all, on our common stock. For example, in the fourth quarter of 2002, our Board of Directors substantially reduced the amount of our quarterly dividend from the levels we had been paying in previous quarters. The declaration and payment of dividends, if any, and the amount of any such dividends depend upon matters deemed relevant by our Board of Directors on a quarterly basis, such as our results of operations, financial condition, cash requirements, future prospects, any limitations imposed by law, credit agreements or debt securities, and other factors deemed relevant and appropriate. If we reduce the amount of dividends paid, or stop paying dividends, the price of our common stock could be adversely affected.
We intend to utilize all or a portion of the net proceeds from this offering for general corporate purposes, including investments in capital projects and acquisition opportunities. We also may use a portion of the net proceeds to reduce our outstanding liabilities, including through voluntary contributions to our defined benefit pension trust or by the repayment or repurchase of long-term debt. Consequently, management will retain significant discretion over the application of these proceeds. To the extent we elect to repay long-term debt, we may have to pay premiums over the par value of such debt in connection with such repayments. The decisions concerning the use of these proceeds will be based on numerous factors and considerations and our actual use of the proceeds may vary substantially from our current intentions as described in "Use of Proceeds."
The offering price of our common stock in this offering is considerably more than the net tangible book value per share of our outstanding common stock. Accordingly, investors purchasing shares of our common stock in this offering will pay a price per share that substantially exceeds the value of our assets after subtracting liabilities. In addition, to the extent that we issue additional shares in the future pursuant to stock options or otherwise, you may experience further dilution.
Sales of a substantial number of shares of our common stock in the public market or otherwise, by us or a major stockholder, could depress the market price of our common stock and impair our ability to raise capital through the sale of additional equity securities. Other than our directors and executive officers, who have agreed not to sell shares of our common stock for 90 days following this offering except with the consent of J.P. Morgan Securities Inc. and Citigroup Global Markets Inc., none of our existing stockholders has agreed to refrain from making sales of our common stock following this offering.
Our Restated Certificate of Incorporation and Amended and Restated Bylaws contain provisions that could make it more difficult for a third party to acquire, or attempt to acquire, control of our company, even if a change of control was considered favorable by you and other stockholders. For instance, our Restated Certificate of Incorporation provides that:
- our Board of Directors is classified into three classes;
- in addition to the requirements of law and the other provisions of our Restated Certificate of Incorporation, the affirmative vote of at least two-thirds of the outstanding shares of our common stock is required for the adoption or authorization of any of the following events unless the event has been approved at a meeting of our Board of Directors by the vote of more than two-thirds of the incumbent members of our Board of Directors:
- any merger or consolidation of us with or into any other corporation;
- any sale, lease, exchange, transfer or other disposition, but excluding a mortgage or any other security device, of all or substantially all of our assets;
- any merger or consolidation of a Significant Shareholder (as defined in our Restated Certificate of Incorporation) with or into us or a direct or indirect subsidiary of ours;
- any sale, lease, exchange, transfer or other disposition to us or to a direct or indirect subsidiary of ours of any of our common stock held by a Significant Shareholder or any other assets of a Significant Shareholder which, if included with all other dispositions consummated during the same fiscal year of ours by the same Significant Shareholder, would result in dispositions of assets having an aggregate fair value in excess of five percent of our total consolidated assets as shown on our certified balance sheet as of the end of the fiscal year preceding the proposed disposition;
- any reclassification of our common stock, or any re-capitalization involving our common stock, consummated within five years after a Significant Shareholder becomes a Significant Shareholder, whereby the number of outstanding shares of common stock is reduced or any of those shares are converted into or exchanged for cash or other securities;
- any dissolution; and
- any agreement, contract or other arrangement providing for any of these transactions but, notwithstanding anything in our Restated Certificate of Incorporation to the contrary, not including any merger pursuant to the Delaware General Corporation Law, as amended from time to time, which does not require a vote of our stockholders for approval;
- our stockholders may not adopt, amend or repeal our Amended and Restated Bylaws other than by the affirmative vote of 75% of the combined voting power of all of our outstanding voting securities entitled to vote generally in an election of directors, voting together as a single class;
- any action required or permitted to be taken by our stockholders must be effected at a duly called annual or special meeting of stockholders and may not be effected by the written consent of the stockholders; and
- special meetings of the stockholders may be called at any time by a majority of our directors and may not be called by any other person or persons or in any other manner.
In addition, we are subject to the anti-takeover provisions of section 203 of the Delaware General Corporation Law, which regulates corporate acquisitions. These provisions could discourage potential acquisition proposals and could delay or prevent a change in control transaction. They could also have the effect of discouraging others from making tender offers for our common stock. These provisions may also prevent changes in our management.
We are a party to a Rights Agreement (the "Rights Agreement") between us and Mellon Investor Services LLC, as successor in interest to ChaseMellon Shareholder Services, L.L.C., as Rights Agent. The terms of the Rights Agreement could further discourage others from making tender offers for our common stock. See "Description of Capital Securities -- Preferred Stock -- Preferred Stock Purchase Rights" in the accompanying prospectus for a description of the terms of the Rights Agreement.
You should carefully review the information contained in or incorporated by reference into this prospectus supplement and accompanying prospectus. In this prospectus supplement and accompanying prospectus, statements that are not reported financial results or other historical information are "forward-looking statements." Forward-looking statements give current expectations or forecasts of future events and are not guarantees of future performance. They are based on our management's expectations that involve a number of business risks and uncertainties, any of which could cause actual results to differ materially from those expressed in or implied by the forward-looking statements.
You can identify these forward-looking statements by the fact that they do not relate strictly to historic or current facts. They use words such as "anticipates," "believes," "estimates," "expects," "would," "should," "will," "will likely result," "forecast," "outlook," "projects," and similar expressions in connection with any discussion of future operating or financial performance. We cannot guarantee that any forward-looking statements will be realized, although we believe that we have been prudent in our plans and assumptions. Achievement of future results is subject to risks, uncertainties and assumptions that may prove to be inaccurate. Among others, the factors discussed in "Risk Factors" in this prospectus supplement or the accompanying prospectus could cause actual results to differ from those in forward-looking statements included in or incorporated by reference into this prospectus supplement or accompanying prospectus or that we otherwise make. Should known or unknown risks or uncertainties materialize, or should underlying assumptions prove to be inaccurate, actual results could vary materially from those anticipated, estimated or projected. You should bear this in mind as you consider any forward-looking statements.
We undertake no obligation to publicly update forward-looking statements, whether as a result of new information, future events or otherwise, except as may be required by law. You are advised, however, to consider any additional disclosures that we may make on related subjects in future filings with the SEC. You should understand that it is not possible to predict or identify all factors that could cause our actual results to differ. Consequently, you should not consider any list of factors to be a complete set of all potential risks or uncertainties.
We estimate the net proceeds to us of this offering will be approximately $169.7 million, assuming a public offering price of $17.80 per share and after payments of estimated underwriting discounts and commissions and estimated expenses of this offering. If the underwriters' overallotment option is exercised in full, we anticipate that the net proceeds to us will be $195.2 million, in the aggregate.
We intend to use a portion of the net proceeds from this offering to enhance our abilities to make growth-oriented investments, including capital investments and acquisitions that we believe will offer attractive returns. We also intend to use a portion of the net proceeds to strengthen our balance sheet by reducing our outstanding liabilities, which may include making voluntary contributions to our defined benefit pension trust or the repayment or repurchase of our long-term debt securities. We may repurchase this debt (pursuant to open market transactions or one or more public tender offers and subsequent retirement), by redeeming it in accordance with its terms, by repaying it on its scheduled maturity dates or by any combination of these methods. We may also use a portion of the net proceeds for other general corporate purposes.
We may apply the net proceeds as described above in one or more transactions from time to time at our discretion. Until we so use the net proceeds, we intend to invest them in short-term, investment grade interest- bearing securities or obligations of, or guaranteed by, the U.S. government.
A listing of our outstanding debt and pension liabilities as of December 31, 2003 are included in Notes 3 and 8 to our consolidated financial statements included in our Annual Report on Form 10-K for the fiscal year ended December 31, 2003, which report is incorporated by reference into this prospectus supplement.
Our common stock is listed on the New York Stock Exchange. The following table sets forth, for the periods indicated, the range of high and low sales prices per share of our common stock as reported on the New York Stock Exchange and the cash dividends declared on the common stock for the periods indicated.
HIGH LOW DIVIDENDS
------ ------ ---------
Year Ended December 31, 2002:
First Quarter........................................... $17.10 $14.72 $0.20
Second Quarter.......................................... 19.10 15.08 0.20
Third Quarter........................................... 15.86 6.20 0.20
Fourth Quarter.......................................... 7.66 5.21 0.06
Year Ended December 31, 2003:
First Quarter........................................... $ 6.85 $ 2.10 $0.06
Second Quarter.......................................... 7.54 2.88 0.06
Third Quarter........................................... 8.30 5.95 0.06
Fourth Quarter.......................................... 14.00 6.55 0.06
Year Ended December 31, 2004:
First Quarter........................................... $13.94 $ 8.64 $0.06
Second Quarter.......................................... 18.40 9.17 0.06
Third Quarter (through July 9, 2004).................... 18.30 17.36 --
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On July 9, 2004, the last sale price of our common stock as reported on the New York Stock Exchange was $17.80 per share. On June 30, 2004, there were 7,363 holders of record of our common stock.
The payment of dividends, if any, and the amount of such dividends depends upon matters deemed relevant by our Board of Directors on a quarterly basis, such as our results of operations, financial condition, cash requirements, future prospects, any limitations imposed by law, credit agreements or debt securities, and other factors deemed relevant and appropriate. While we have historically paid cash dividends on our common stock on a quarterly basis, no assurance can be given that we will continue to pay dividends on our common stock in a manner and amount consistent with our historic practices, or at all, in the future. See "Risk Factors -- Risks Relating to this Offering -- Payment of dividends on our common stock in the future is not assured."
The following table sets forth our consolidated capitalization as of March 31, 2004:
- on an actual basis;
- on a pro forma basis to give effect to the acquisition of substantially all of the assets of J&L Specialty Steel, including the incurrence of indebtedness, the amount of which is subject to possible adjustment in the future; and
- (1) on a pro forma basis to give effect to the acquisition of substantially all of the assets of J&L Specialty Steel, including the incurrence of indebtedness, the amount of which is subject to possible adjustment in the future, and (2) on a pro forma as adjusted basis to reflect the sale of 10,000,000 shares of our common stock offered by us at an assumed public offering price of $17.80 per share, after deducting estimated underwriting discounts and commissions and estimated offering expenses payable by us.
AS OF MARCH 31, 2004
---------------------------------
PRO FORMA
ACTUAL PRO FORMA AS ADJUSTED
------- --------- -----------
(DOLLARS IN MILLIONS)
Short-term debt and current portion of long-term
debt................................................ $ 21.8 $ 32.2 $ 32.2
Long-term debt........................................ 512.4 566.4 566.4
Stockholders' equity:
Preferred stock, par value $0.10; 50,000,000 shares
authorized; none issued.......................... -- -- --
Common stock, par value $0.10; 500,000,000 shares
authorized; 98,951,490 shares issued; 81,247,476
shares outstanding; 98,951,490 shares issued and
91,247,476 shares outstanding, as adjusted....... 9.9 9.9 9.9
Additional paid-in-capital.......................... 481.2 481.2 481.2
Retained earnings................................... 418.9 418.9 338.1
Treasury stock, at cost; 17,704,014 shares;
7,704,014 shares, as adjusted.................... (443.5) (443.5) (193.0)
Accumulated other comprehensive loss, net of tax.... (330.2) (330.2) (330.2)
------- ------- -------
Total stockholders' equity....................... 136.3 136.3 306.0
------- ------- -------
Total capitalization........................... $ 670.5 $ 734.9 $ 904.6
======= ======= =======
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We derived the selected consolidated financial data shown below as of December 31, 2001, 2002 and 2003 and for each of the years in the three-year period ended December 31, 2003 from our audited consolidated financial statements and for the three month periods ended March 31, 2003 and 2004 from our unaudited consolidated financial statements. The unaudited financial statements from which we derived this data were prepared on the same basis as the audited consolidated financial data and include all adjustments, consisting only of normal recurring adjustments, necessary to present fairly our results of operations and financial condition as of the periods presented. The results of operations for interim periods are not necessarily indicative of the operating results for any future period. You should read the following financial information in conjunction with "Management's Discussion and Analysis of Financial Condition and Results of Operations" and our consolidated financial statements and the related notes included elsewhere or incorporated by reference in this prospectus supplement.
THREE MONTHS
YEAR ENDED DECEMBER 31, ENDED MARCH 31,
------------------------------ -------------------
2001 2002 2003 2003 2004
-------- -------- -------- -------- --------
(DOLLARS IN MILLIONS EXCEPT OPERATING DATA AND AS
OTHERWISE INDICATED)
STATEMENT OF INCOME DATA:
Sales
Flat-Rolled Products................................. $1,080.4 $1,040.3 $1,043.5 $ 257.3 $ 329.6
High Performance Metals.............................. 771.8 630.0 641.7 161.0 178.7
Engineered Products.................................. 275.8 237.5 252.2 62.2 69.5
-------- -------- -------- -------- --------
Sales.............................................. $2,128.0 $1,907.8 $1,937.4 $ 480.5 $ 577.8
Operating profit (loss):
Flat-Rolled Products................................. $ (40.0) $ (8.6) $ (14.1) $ (1.3) $ (11.0)
High Performance Metals.............................. 82.0 31.2 26.2 8.3 7.8
Engineered Products.................................. 12.3 4.7 7.8 1.8 3.8
-------- -------- -------- -------- --------
Operating profit................................... $ 54.3 $ 27.3 $ 19.9 $ 8.8 $ 0.6
Loss before cumulative effect of change in accounting
principle............................................ $ (25.2) $ (65.8) $ (313.3) $ (25.8) $ (50.4)
Net loss............................................... $ (25.2) $ (65.8) $ (314.6) $ (27.1) $ (50.4)
BALANCE SHEET DATA (AT END OF PERIOD):
Working capital...................................... $ 574.0 $ 453.7 $ 348.6 $ 480.3 $ 334.1
Total assets......................................... 2,643.2 2,093.2 1,884.9 2,106.6 1,941.3
Total debt........................................... 582.2 519.1 532.1 520.9 534.2
Long-term debt....................................... 573.0 509.4 504.3 510.9 512.4
Stockholders' equity................................. 944.7 448.8 174.7 422.2 136.3
CASH FLOW INFORMATION:
Cash flow provided by (used in) operating
activities......................................... $ 122.8 $ 204.2 $ 82.0 $ 45.2 $ (0.2)
Cash flow used in investing activities............... (85.0) (39.8) (70.3) (5.9) (10.9)
Cash flow provided by (used in) financing
activities......................................... (30.3) (138.7) 8.5 12.7 (1.2)
OPERATING DATA:
Volume:
Flat-Rolled Products (finished tons)................. 498,066 487,335 478,353 118,964 124,987
High Performance Metals -- nickel-based and specialty
steel alloys (000's lbs.).......................... 51,899 35,832 35,168 8,692 8,944
High Performance Metals -- titanium mill products
(000's lbs.)....................................... 23,070 19,044 18,436 4,615 5,023
High Performance Metals -- exotic alloys (000's
lbs.).............................................. 3,457 3,712 4,245 932 1,185
Average Prices:
Flat-Rolled Products (per finished ton).............. $ 2,162 $ 2,134 $ 2,178 $ 2,158 $ 2,636
High Performance Metals -- nickel-based and specialty
steel alloys (per lb.)............................. 6.31 6.39 6.57 6.73 7.73
High Performance Metals -- titanium mill products
(per lb.).......................................... 11.70 11.83 11.50 12.85 11.41
High Performance Metals -- exotic alloys (per lb.)... 33.52 36.29 37.64 37.75 36.32
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The following discussion should be read in conjunction with our consolidated financial statements and notes to those consolidated financial statements, incorporated by reference into this prospectus supplement.
OVERVIEW
We believe that we are one of the largest and most diversified producers of specialty materials in the world. Unless the context requires otherwise, "we", "our" and "us" refer to Allegheny Technologies Incorporated and its subsidiaries.
RESULTS OF OPERATIONS
Our three business segments accounted for the following percentages of total external sales for the first three months of 2003 and 2004:
THREE MONTHS
ENDED MARCH 31,
---------------
2003 2004
---- ----
Flat-Rolled Products........................................ 54% 57%
High Performance Metals..................................... 34% 31%
Engineered Products......................................... 12% 12%
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For the first three months of 2004, operating profit decreased to $0.6 million compared to $8.8 million for the same 2003 period, primarily due to higher raw material costs. Results included a LIFO inventory valuation reserve increase of $48.1 million, primarily due to the effects of rapidly rising raw materials costs, which increased approximately 30% in the first quarter 2004 compared to the fourth quarter 2003. The higher raw material costs more than offset the benefits of additional surcharges, higher base selling prices and cost reduction initiatives. Cost reductions, before the effects of inflation, totaled $26.6 million in the first quarter 2004. First quarter 2003 results included a LIFO inventory valuation reserve increase of $3.0 million. Sales increased 20% to $577.8 million for the first three months of 2004 compared to $480.5 million for the same 2003 period. During the first quarter 2004, we increased base selling prices for most of our products and implemented additional surcharges for certain raw materials for many of our products.
Business conditions in most of our end markets reflected increased demand for many of our products during the first quarter of 2004. These improved market conditions were offset by higher raw material and retirement benefit expenses, which resulted in a net loss of $50.4 million, or $0.63 per diluted share, for the first three months of 2004 compared to a net loss before cumulative effect of a change in accounting principle of $25.8 million, or $0.32 per diluted share, for the first three months of 2003. First quarter 2004 results do not include an income tax benefit as a result of a deferred tax valuation allowance recorded in the fourth quarter 2003. First quarter 2003 results included an income tax benefit of $14.2 million, or $0.18 per share. Retirement benefit expense was $36.0 million in the first quarter of 2004, compared to $34.8 million in the comparable 2003 period. Essentially all of this $1.2 million increase in expense is non-cash.
On January 1, 2003, we adopted Statement of Financial Accounting Standards No. 143, "Accounting for Asset Retirement Obligations" ("SFAS 143"). The adoption of SFAS 143 resulted in an after-tax charge of $1.3 million or $0.02 per diluted share. This charge is reported as a cumulative effect of a change in accounting principle.
Sales and operating profit (loss) for our three business segments are discussed below.
Sales increased 28% to $329.6 million in the 2004 first quarter, compared to the prior year period, primarily due to improved demand from capital goods markets, and the impact of higher raw material surcharges and base selling price increases. Higher raw material and energy costs more than offset the benefits of additional surcharges, higher base selling prices and cost reduction initiatives, resulting in an operating loss of $11.0 million for the quarter, compared to an operating loss of $1.3 million in the comparable 2003 period. Higher raw material costs resulted in a LIFO inventory valuation reserve increase of $37.6 million in the first quarter 2004 compared to a LIFO inventory valuation reserve increase of $3.9 million in the comparable 2003 period. Energy costs increased by $2.4 million compared to 2003, net of approximately $0.4 million in gains from natural gas derivatives, as a result of higher natural gas and electricity prices. Results for 2004 benefited from $13 million in gross cost reductions, before the effects of inflation.
For the first quarter of 2004, total tons shipped increased 5% compared to the same period of 2003. For the comparable periods, shipments of commodity products increased 4% and shipments of high-value products increased 7%. Average transaction prices for the comparable periods, which include raw material surcharges, were 22% higher. Average base selling prices for the first quarter of 2004, which exclude surcharges, increased by approximately 3% compared to the first quarter of 2003.
Comparative information on the segment's products is provided in the following table (unaudited):
THREE MONTHS ENDED
MARCH 31,
------------------- %
2003 2004 CHANGE
-------- -------- ------
Volume (finished tons):
Commodity.............................................. 83,492 87,016 4%
High Value............................................. 35,472 37,971 7%
------- -------
Total.................................................. 118,964 124,987 5%
======= =======
Average prices (per finished ton):
Commodity.............................................. $1,563 $2,006 28%
High Value............................................. $3,557 $4,081 15%
Combined Average....................................... $2,158 $2,636 22%
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Sales increased 11% to $178.7 million primarily due to improved demand from the commercial aerospace market for nickel-based superalloys and titanium alloys. Our exotic alloys business continued to benefit from sustained high demand from government and high energy physics markets and corrosion markets, particularly in Asia. Operating profit declined to $7.8 million compared to $8.3 million in the year-ago period because the impact of higher raw material costs offset increased sales and the benefits of cost reduction initiatives. The rise in raw material costs resulted in a LIFO inventory valuation reserve increase of $8.6 million in 2004, compared to $1.0 million in the first quarter 2003. Results for 2004 benefited from $10 million of gross cost reductions, before the effects of inflation.
Shipments were up 3% for nickel-based and specialty steel alloys, 9% for titanium alloys, and 27% for exotic alloys compared to the same period of 2003.
THREE MONTHS
ENDED MARCH 31,
--------------- %
2003 2004 CHANGE
------ ------ ------
Volume (000's pounds):
Nickel-based and specialty steel alloys.................. 8,692 8,944 3 %
Titanium mill products................................... 4,615 5,023 9 %
Exotic alloys............................................ 932 1,185 27 %
Average prices (per pound):
Nickel-based and specialty steel alloys.................. $ 6.73 $ 7.73 15 %
Titanium mill products................................... $12.85 $11.41 (11)%
Exotic alloys............................................ $37.75 $36.32 (4)%
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Sales improved 12% to $69.5 million. Operating profit improved to $3.8 million for the first quarter of 2004 compared to $1.8 million in the prior year quarter. Higher sales volumes, improved pricing, and the benefits from cost reductions offset higher raw material costs. The rise in raw material costs resulted in an increase to the LIFO inventory valuation reserve of $1.9 million in 2004, compared to a decrease of $1.9 million in 2003. Gross cost reductions, before the effects of inflation, totaled $2 million in the first quarter 2004. Demand for tungsten products in our Metalworking Products operation remained strong from the oil and gas market and demand improved for tungsten carbide products and cutting tools due to a pickup in overall manufacturing activity. Demand improved considerably for forged products from the Class 8 truck market and for cast products from the improving manufacturing sector and transportation and wind energy markets.
Corporate expenses increased to $5.6 million for the first quarter of 2004 compared to $4.8 million for the first quarter of 2003. This increase is due primarily to non-cash expenses associated with our stock-based long-term incentive compensation programs, which offset savings associated with reductions in staffing and other efforts to control costs at the corporate office. Net interest expense increased to $8.2 million for the first quarter of 2004 from $7.4 million for the same period last year. The increase was primarily due to higher costs associated with the secured credit facility we entered into in June 2003. Our "receive fixed, pay floating" interest rate swap contracts for $150 million related to the $300 million, 8.375%, ten-year Notes, which effectively convert this portion of the Notes to variable rate debt, decreased interest expense by $1.7 million in both periods, compared to the fixed interest expense of the Notes that would otherwise be applicable.
Retirement benefit expense was $36.0 million in the first quarter 2004, compared to $34.8 million in the first quarter 2003. Pension expense decreased to $19.0 million for the 2004 first quarter from $23.4 million for same period of last year as actual returns on pension assets in 2003 were higher than expected, partially offset by the use in 2004 of a lower assumed discount rate to value pension benefit liabilities. However, other postretirement benefit expense increased for the 2004 first quarter to $17.0 million from $11.4 million in the comparable 2003 period as a result of a projected rise in medical cost inflation and a lower assumed discount rate. Approximately $29.7 million of the first quarter 2004 retirement benefit expense was non-cash. The 2004 retirement benefit expense does not include the expected favorable impact on our postretirement medical expense from the enactment of the Federal Medicare prescription drug benefit program in December 2003, pending final authoritative accounting guidance regarding how the benefit is to be recognized in the financial statements. For the first quarter 2004, retirement benefit expense increased cost of sales by $27.6 million, and selling and administrative expenses by $8.4 million. For the first quarter 2003, retirement benefit expense increased cost of sales by $24.4 million, and selling and administrative expenses by $10.4 million.
First quarter 2004 results do not include an income tax benefit as a result of a deferred tax valuation allowance recorded in the fourth quarter 2003. The valuation allowance was recorded in accordance with SFAS No. 109, "Accounting for Income Taxes", based upon the results of our quarterly evaluation concerning the estimated probability that the net deferred tax asset would be realizable. We are required to maintain a valuation allowance until a realization event occurs to support reversal of all or a portion of the allowance. Our effective tax rate was a benefit of 35.5% for the 2003 first quarter. We received federal income tax refunds of $6.9 million and $48.3 million in the 2004 and 2003 first quarters, respectively. Under current tax laws we are substantially unable to carry-back any current year or future year tax losses to prior periods to obtain cash refunds of taxes paid during those periods. Current year tax losses, if any, can be carried forward for up to 20 years and applied against any taxes owed in those future years.
Effective January 1, 2003, as required, we adopted SFAS 143. Under SFAS 143, obligations associated with the retirement of tangible long-lived assets, such as landfill and other facility closure costs, are capitalized and amortized to expense over an asset's useful life using a systematic and rational allocation method.
Our adoption of SFAS 143 resulted in recognizing a charge of $1.3 million, net of income taxes of $0.7 million, or $0.02 per share, principally for asset retirement obligations related to landfills in our Flat-Rolled Products segment. This charge is reported in the statement of operations for the quarter ended March 31, 2003, as a cumulative effect of a change in accounting principle.
Our three business segments accounted for the following percentages of total external sales for 2003 and 2002:
YEAR ENDED
DECEMBER 31,
-------------
2002 2003
---- ----
Flat-Rolled Products........................................ 55% 54%
High Performance Metals..................................... 33% 33%
Engineered Products......................................... 12% 13%
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Sales were $1.94 billion in 2003 and $1.91 billion in 2002. International sales represented approximately 23% of total sales for both years.
Operating profit was $19.9 million in 2003 and $27.3 million in 2002. Losses before taxes were $280.2 million and $103.8 million, respectively. These results included restructuring charges and litigation expense in 2003 of $84.9 million, and restructuring charges of $42.8 million in 2002.
Net losses, before the cumulative effect of change in accounting principle, were $313.3 million and $65.8 million for 2003 and 2002, respectively. The net loss for 2003 included a $138.5 million charge for a valuation allowance on our net deferred tax assets, pretax restructuring charges of $62.4 million relating to asset impairments in the Flat-Rolled Products segment and workforce reductions across all operating segments and the corporate office, and $22.5 million for litigation expense. As a result of recording the deferred tax valuation allowance, results for 2003 include an income tax provision of $33.1 million, whereas 2002 pretax losses were reduced by income tax benefits of $38.0 million. Charges of $42.8 million in 2002 related to the indefinite idling of our Massillon, Ohio stainless steel plate facility in the Flat-Rolled Products segment and workforce reductions.
YEAR ENDED
DECEMBER 31,
-------------------
2002 2003 % CHANGE
-------- -------- --------
(DOLLARS IN MILLIONS)
Sales to external customers........................... $1,040.3 $1,043.5 0.3 %
Operating loss........................................ (8.6) (14.1) (64.0)%
Operating loss as a percentage of sales............... (0.8)% (1.4)%
International sales as a percentage of sales.......... 11.8% 13.5 %
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Sales for the Flat-Rolled Products segment for 2003 were $1,043.5 million, essentially the same as 2002, which was due primarily to the effect of raw material surcharges offsetting lower volumes and base selling prices. Weak demand and base pricing for products of the Flat-Rolled Products segment, especially commodity stainless steel, which persisted for most of 2003, plus the negative effects of rapidly rising raw material costs and higher energy costs resulted in an operating loss of $14.1 million for 2003 compared to an operating loss of $8.6 million in 2002.
Finished tons shipped in 2003 declined by 2% to 478,353 tons compared to shipments of 487,335 tons for 2002. The average transaction prices to customers increased by 2% to $2,178 per ton in 2003 due primarily to higher raw materials surcharges, which offset a 4% decline in average base selling prices, which exclude the affect of surcharges. Shipments of commodity products (including stainless steel hot roll and cold roll sheet, stainless steel plate and silicon electrical steel, among other products) decreased 2% while average prices for these products increased 3%. The decline in shipments was primarily attributable to continued depressed demand for commodity stainless steel sheet and plate due to the continued weakness in the U.S. industrial economy, especially in the non-residential construction and most capital goods markets. The increase in average prices was primarily due to higher raw material surcharges, principally for nickel. Commodity stainless steel base selling prices, which exclude surcharges, declined 4% in 2003 compared to 2002. During the same period, consumption in the U.S. of stainless steel strip, sheet and plate products was flat according to the Specialty Steel Institute of North America ("SSINA"). High-value product shipments in the segment (including strip, Precision Rolled Strip(R), super stainless steel, nickel alloy and titanium products) decreased 1%, while average prices for high-value products were flat. Increased shipments of Precision Rolled Strip(R) products in Europe and Asia were partially offset by the overall decline in shipments of other high-value products. Certain of these high-value products are used in the consumer durables and capital goods markets, both of which continued to be impacted by the weak U.S. economy in the markets we serve, which negatively affected shipments.
Operating results for 2003 were adversely affected by higher raw material costs, which increased significantly in 2003, especially during the second half of the year. For example, the cost of nickel, a major raw material in the production of many stainless steel alloys, increased 97% in 2003 from an average cost of $3.26 per pound for the month of December 2002 to an average cost of $6.43 per pound for December 2003, as priced on the London Metals Exchange. While we were able to offset a significant portion of the increase through raw material surcharges in the pricing of our products, these higher costs had a negative effect on cost of sales as a result of our LIFO inventory accounting methodology. For 2003, we incurred approximately $36 million of expense for these cost increases, including LIFO inventory charges of $27 million and cost increases of $9 million for certain raw materials which are not subject to our surcharges. In addition, natural gas and electricity costs for 2003 were approximately $12 million higher than for 2002.
We continued to aggressively reduce costs and streamline our operations. In 2003, we achieved gross cost reductions, before the effects of inflation, of $60 million. Major areas of cost reductions, before the effects of inflation, included $19 million from operating efficiencies, $18 million from procurement, $13 million from lower compensation and fringe benefit expenses, and $10 million from reduced depreciation expense and other fixed cost savings. During 2003, we implemented further workforce reductions of approximately 140 salaried employees representing approximately 13% of the salaried workforce. These workforce reductions were substantially complete by the end of 2003 and resulted in a pretax severance charge of $5 million in 2003. In addition, we indefinitely idled our Washington Flat-Rolled coil facility located in Washington, Pennsylvania and recorded an asset impairment charge related to the remaining assets located at Houston, Pennsylvania reflecting projected utilization. These actions resulted in a total pretax, non-cash asset impairment charge of $47.5 million in the 2003 fourth quarter. These expenses are presented as restructuring costs on the statement of operations and are not included in the results for the segment. These cost reduction actions are expected to result in annual pretax cost savings of approximately $10 million. Since 2000, the salaried workforce has been reduced by approximately 41%.
We continued to invest to enhance our specialty metals capabilities, increase efficiencies and reduce costs. Our strategic capital investment to upgrade the Brackenridge, Pennsylvania melt shop, which commenced in 2002 and is expected to cost approximately $35 million, is on schedule. The first of the two new electric arc furnaces began operation in November 2003 and the second furnace is scheduled to be completed in the second half of 2004. Cost savings are estimated to be over $20 million annually after completion of the project.
YEAR ENDED
DECEMBER 31,
-----------------
2002 2003 % CHANGE
------ ------ --------
(DOLLARS IN MILLIONS)
Sales to external customers.......................... $630.0 $641.7 1.9 %
Operating profit..................................... 31.2 26.2 (16.0)%
Operating profit as a percentage of sales............ 5.0% 4.1%
International sales as a percentage of sales......... 39.3% 34.8%
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Sales for the High Performance Metals segment increased 1.9% to $641.7 million in 2003 primarily due to strong demand for our exotic materials, especially for the government and chemical processing markets, which offset continued weakness in the commercial aerospace and land-based turbine power generation markets. However, operating profit for the High Performance Metals segment declined 16% to $26.2 million because of lower demand and prices for nickel-based alloys and superalloys, specialty steel alloys and titanium-based alloys, which represent approximately 70% of the segment's sales. In addition, rising raw material costs offset cost reduction efforts.
Shipments of nickel-based and specialty steel alloys decreased 2%, while average prices increased 3% primarily due to product mix. Titanium mill products shipments decreased 3% and average prices decreased 3%. Shipments for exotic alloys increased 14% and average prices increased 4%. Backlog of confirmed orders for the segment was approximately $270 million at December 31, 2003 and approximately $300 million at December 31, 2002.
Operating profit for 2003 was adversely affected by higher raw material costs, which increased significantly in 2003, especially during the second half of the year. These higher costs had a negative effect on cost of sales as a result of our LIFO inventory accounting methodology, resulting in $11.7 million of expense for 2003, compared to $7.4 million of LIFO income in 2002. Operating profit in 2002 was adversely impacted by the effects of a seven month labor strike settled in March 2002 at our Wah Chang operation, which produces our exotic alloys.
We continued to aggressively reduce costs in 2003. Gross cost reductions, before the effects of inflation, for 2003 totaled approximately $45 million. Major areas of cost reductions, before the effects of inflation, included $23 million from operating efficiencies, $13 million from procurement, and $9 million from hourly and salary labor cost savings. During 2003, we implemented further workforce reductions, which affected approximately 200 employees, or 19% of the salaried workforce. In connection with these reductions, which were substantially completed by the end of the year, we recorded charges of $3 million for the related severance costs. These expenses are presented as restructuring costs on the statement of operations and are not included in the results for the segment. These cost reduction actions are expected to result in annual pretax cost savings of approximately $10 million.
Sales for the Engineered Products segment increased 6.2%, to $252.2 million in 2003, compared to 2002, and operating profit increased 65.5%, to $7.8 million. Demand for our tungsten products from the oil and gas, medical and automotive markets improved during 2003. Demand also improved for forgings and castings. Segment operating profit improved primarily due to higher sales and the impact of cost reductions, which totaled $9 million in 2003.
In the second half of 2003, we announced an additional restructuring of the European operations of Metalworking Products. Restructuring charges of approximately $3 million associated with this consolidation are presented as restructuring costs on the 2003 statement of operations and are not included in segment results. These cost reductions are expected to result in $2 million in annual pretax cost savings.
Corporate expenses
Corporate expenses were $20.5 million in 2003 compared to $20.6 million in 2002. Cost controls and reductions in the number of corporate employees that were implemented over this period were offset in 2003 by increased compensation expense associated with our long-term, stock-based compensation plan due to the significant increase in our stock price in the 2003 fourth quarter.
Interest expense, net
Interest expense, net of interest income, was $27.7 million for 2003, compared to $34.3 million for 2002. The effect of "receive fixed, pay floating" interest rate swap contracts of $150 million, related to our $300 million of 8.375% ten-year Notes issued in December 2001, decreased interest expense by $6.7 million in 2003 and $4.9 million in 2002, compared to the fixed interest expense of the Notes. Interest expense in 2003 was reduced by $2.1 million from interest capitalization on capital projects.
Interest expense is presented net of interest income of $6.2 million for 2003 and $3.0 million for 2002. The increases in interest income for 2003 and 2002 primarily relate to interest on settlements of prior years' tax liabilities.
Restructuring costs
Restructuring costs were $62.4 million and $42.8 million in 2003 and 2002, respectively.
In 2003, we recorded charges of $62.4 million, including $47.5 million for impairment of long-lived assets in the Flat-Rolled Products segment, $11.1 million for workforce reductions across all business segments and the corporate office, and $3.8 million for facility closure charges including present-valued lease termination costs, net of forecasted sublease rental income, at the corporate office. In the 2003 fourth quarter, based on existing and projected operating levels at our remaining operations in Houston, Pennsylvania and at our Washington Flat Roll coil facility located in Washington, Pennsylvania, we determined that the net book values of these facilities were in excess of their estimated fair market values based on expected future cash flows. Charges for the Houston facility and the Washington Flat Roll coil facility were recorded to write down the net book values of these facilities to their estimated fair market values. These asset impairment charges do not impact current operations at these facilities. The workforce reductions affected approximately 375 employees across all segments and the corporate office. Approximately $5 million of the severance charges will be paid from the Company's pension plan, and at December 31, 2003, approximately $9 million of the workforce reduction and facility closure charges are future cash costs that will be paid over the next ten years. Cash to meet these obligations is expected to be generated from one or more of the following sources: internally generated funds from operations, current cash on hand, or borrowings under existing credit lines.
In 2002, we recorded total charges of $42.8 million related to the indefinite idling of our Massillon, Ohio stainless steel plate facility, due to continuing poor demand for wide, continuous, mill plate products, and further workforce reductions across all of our operations. The Massillon, Ohio stainless steel plate facility was indefinitely idled in the 2002 fourth quarter, and resulted in a pretax non-cash asset impairment charge of $34.4 million, representing the excess of the book value of the facility over its estimated fair market value. In addition, during the second half of 2002, and in light of continuing weak demand in the markets we serve, we announced workforce reductions of approximately 665 employees. These workforce reductions were substantially complete by the end of the first half of 2003, and resulted in a pretax, primarily cash, severance charge of $8.4 million, net of a retirement benefits curtailment gain. These expenses are presented as restructuring costs on the statement of operations and are not included in segment results. Of the $42.8 million restructuring charge recorded in 2002, $8.4 million resulted in expenditures of cash.
At December 31, 2003, substantially all cash expenditures related to the 2002 restructuring charges had been paid.
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 statement of operations and resulted in net charges of $47.7 million and $11.6 million in 2003 and 2002, respectively.
In 2003, charges for closed companies related to legal, environmental, insurance and other matters were approximately $30 million higher than in 2002. These charges include $22.5 million related to litigation, as more fully described in Note 14, "Commitments and Contingencies", in the Notes to Consolidated Financial Statements, and which is included in selling and administrative expenses in the consolidated statement of operations; and changes in our estimates of our liability for environmental closure costs and for liabilities under retrospectively-rated insurance programs. In 2002, we recognized a pretax charge of $6.5 million for our approximate 30% share of the net losses in New Piper Aircraft and for the write-off of the carrying value of this investment.
Retirement benefit (expense) income
Retirement benefit expenses have increased significantly over the past three years due to lower pension investments as a result of severe declines in the equity markets in 2000 through 2002, and higher benefit liabilities from long-term labor contracts negotiated in 2001. Retirement benefit expense was $134.4 million for 2003 and $21.8 million for 2002, compared to pretax retirement benefit income of $53.1 million for 2001. The increases in retirement benefit expenses have negatively affected both cost of sales and selling and administrative expenses. The effect of retirement benefit (expense) income on cost of sales and selling and administrative expenses for the years ended 2003, 2002 and 2001 were as follows:
YEAR ENDED DECEMBER 31,
------------------------
2001 2002 2003
----- ------ -------
(DOLLARS IN MILLIONS)
Cost of sales............................................... $45.9 $ 9.9 $ (94.6)
Selling and administrative expenses......................... 7.2 (11.9) (39.8)
----- ------ -------
Total retirement benefit expense............................ $53.1 $(21.8) $(134.4)
===== ====== =======
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Retirement benefit expenses for 2004 are expected to be approximately $143 million, with effects on cost of sales and selling and administrative expenses similar to 2003. Pension expense is expected to decline to approximately $75 million pretax for 2004 from $92 million for 2003 as actual returns on pension assets in 2003 were higher than expected, partially offset by a lower assumed discount rate to value pension benefit liabilities. The projected rise in medical benefit inflation and lower assumed discount rate is expected to result in postretirement medical expenses of approximately $68 million for 2004 compared to $42 million of 2003. The projected 2004 postretirement medical expense does not include the expected favorable impact of the Medicare Prescription Drug, Improvement and Modernization Act (the "Medicare Act"), which was signed into law on December 8, 2003. The Medicare Act provides for a federal subsidy, with tax-free payments commencing in 2006, to sponsors of retiree health care benefits plans that provide a benefit that is at least actuarially equivalent to the benefit established by the law. Based upon estimates from our actuaries, we expect that the federal subsidy included in the law will result in a reduction in the Other Postretirement Benefits obligation of up to $70 million. This reduction has not been reflected in the 2003 financial statements or in the 2004 estimated expense because authoritative accounting guidance regarding how the reduction in the obligation is to be recognized in the financial statements is pending. Approximately 76%, or $109 million, of the estimated 2004 retirement benefit expense is expected to be non-cash.
In the 2003 fourth quarter we recorded a $138.5 million valuation allowance on 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. This charge did not affect cash or our ability to utilize any of our deferred tax assets on future tax returns. Our income tax provision (benefit) for 2003, 2002, and 2001 was $33.1 million, $(38.0) million and $(11.2) million, respectively. The income tax benefits recognized in 2002 and 2001 include the effects of cash refunds of income taxes paid in prior years. In 2003 and 2002, we received $65.6 million and $45.6 million, respectively, in income tax refunds, and we recognized $7.2 million of income taxes receivable at December 31, 2003, which we expect to receive in the first half of 2004. Under current tax laws we are limited in our ability to carryback any current year or future tax losses to prior periods to obtain cash refunds of taxes paid during those periods. Current year federal tax losses, if any, can be carried forward for up to 20 years and applied against taxes owed in those future years. As of December 31, 2003, we had a federal income tax net operating loss carryforward deferred tax asset of approximately $29 million, which we are able to carryforward until 2023.
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, 2003, we had a net deferred tax asset of $34.3 million, net of a valuation allowance of $178.8 million, including the $138.5 million 2003 fourth quarter deferred tax valuation allowance and previously recorded deferred tax valuation allowances on state income tax net operating loss carryforwards. A significant portion of our deferred tax asset, prior to the valuation allowance, relates to postretirement employee benefit obligations, which have been recorded in the accompanying financial statements but are not recognized for income tax reporting until the benefits are paid. These benefit payments are expected to occur over an extended period of years. No valuation allowance was required on $34.3 million of net deferred tax assets based upon our ability to utilize these assets within the carryback, carryforward period, including consideration of tax planning strategies that we would undertake to prevent an operating loss or tax credit carryforward from expiring unutilized. We intend to maintain a valuation allowance on the net deferred tax assets until a realization event occurs to support the reversal of all or a portion of the reserve.
FINANCIAL CONDITION AND LIQUIDITY
During the three months ended March 31, 2004, cash used by operations was $0.2 million, due primarily to a $75.4 million increase in managed working capital in the quarter, partially offset by the receipt of a $6.9 million Federal income tax refund pertaining to our 2003 tax return. Capital expenditures of $12.1 million, and $3.1 million of net debt repayments were the principal investing and financing activities, respectively. At March 31, 2004, cash and cash equivalents totaled $67.3 million, a decrease of $12.3 million from December 31, 2003.
The components of managed working capital were as follows:
YEAR ENDED DECEMBER 31, THREE MONTHS
------------------------------ ENDED
2001 2002 2003 MARCH 31, 2004
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(DOLLARS IN MILLIONS)
Accounts receivable..................... $ 274.6 $ 239.3 $ 248.8 $ 311.0
Inventory............................... 488.9 392.3 359.7 366.9
Accounts payable........................ (155.3) (171.3) (172.3) (219.4)
-------- -------- -------- --------
Subtotal................................ 608.2 460.3 436.2 458.5
Allowance for doubtful accounts......... 12.3 10.1 10.2 11.0
LIFO reserve............................ 77.2 74.7 111.7 159.8
Corporate and other..................... 21.0 18.6 17.4 21.6
-------- -------- -------- --------
Managed working capital................. $ 718.7 $ 562.7 $ 575.5 $ 650.9
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Annualized prior 2 months sales......... $1,956.0 $1,741.0 $1,874.0 $2,463.0
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Managed working capital as a % of
sales................................. 36.7% 32.4% 30.7% 26.4%
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Capital expenditures for 2004 are expected to be between $60 and $70 million, of which $12.1 million had been expended in the 2004 first quarter. Capital expenditures primarily relate to the upgrade of our flat-rolled products melt shop located in Brackenridge, Pennsylvania and investments to enhance the high performance metals capabilities of our high performance metals long products rolling mill facility located in Richburg, South Carolina.
A regular quarterly dividend of $0.06 per share of common stock was declared on March 11, 2004, payable to stockholders of record at the close of business on March 22, 2004. 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. No assurance can be given that we will continue to pay dividends on your common stock in a manner and amount consistent with our historic practices, or at all, in the future.
At March 31, 2004, we had $534.2 million in total outstanding debt, largely unchanged from the $532.1 million at December 31, 2003. The increase in debt was due to fair value adjustments related to interest rate swap contracts on our $300 million, 8.375% ten-year Notes, due December 15, 2011, which offset a net decrease in other debt of $3.1 million. We repaid $9.5 million in industrial revenue bonds, and borrowed $6.5 million, net, at our STAL joint venture.
Interest rate swap contracts are used from time to time to manage our exposure to interest rate risks. At the end of the 2002 first quarter, we entered into interest rate swap contracts with respect to a $150 million notional amount related to our Notes, which involved the receipt of fixed rate amounts in exchange for floating rate interest payments over the life of the contracts without an exchange of the underlying principal amount. These contracts were designated as fair value hedges. As a result, changes in the fair value of the swap contracts and the underlying fixed rate debt are recognized in the statement of operations. In the 2003 first quarter, we terminated the majority of these interest rate swap contracts and received $14.6 million in cash. The gain on settlement remains a component of the reported balance of the Notes ($313.1 million at March 31, 2004, including fair value adjustments), and is being ratably recognized as a reduction to interest expense over the remaining life of the Notes, which is approximately eight years.
In the 2003 first quarter, we entered into new "receive fixed, pay floating" interest rate swap arrangements related to the Notes that re-established, in total, the $150 million notional amount that effectively converted this portion of the Notes to variable rate debt. Including accretion of the gain on termination of the swap contracts described above, the result of the "receive fixed, pay floating" arrangements was a decrease in interest expense of $1.7 million for both the 2004 and 2003 first quarters, compared to the fixed interest expense of the Notes that would otherwise have been realized. At March 31, 2004, the adjustment of these swap contracts to fair market value resulted in the recognition of an asset of $5.4 million on the balance sheet, included in other assets, with an offsetting increase in long-term debt.
We did not borrow funds under our domestic credit facilities during the 2004 first quarter, or during all of 2003 or 2002. We have a $325 million four-year senior secured domestic revolving credit facility (the "facility"), which expires in June 2007, and which is secured by all accounts receivable and inventory of our U.S. operations, and includes capacity for up to $150 million in letters of credit. Outstanding letters of credit issued under the facility at March 31, 2004 were approximately $94 million. The secured credit facility limits capital expenditures, investments and acquisitions of businesses, new indebtedness, asset divestitures, payment of dividends, and common stock repurchases which we may incur or undertake during the term of the facility without obtaining permission of the lending group. In addition, the secured credit facility contains a financial covenant, which is not measured unless our undrawn availability under the facility is less than $150 million. This financial covenant, when measured, requires us to maintain a ratio of consolidated earnings before interest, taxes, depreciation and amortization ("EBITDA") to fixed charges of at least 1.0 to 1.0. EBITDA is adjusted for non-cash items such as income/loss on investments accounted for under the equity method of accounting, non-cash pension expense/income, and that portion of retiree medical and life insurance expenses paid from our Voluntary Employment Benefit Association (VEBA) trust. EBITDA is reduced by capital expenditures and cash taxes paid, and increased for cash tax refunds. Fixed charges include gross interest expense, dividends paid and scheduled debt payments. Our ability to borrow under the secured credit facility in the future could be adversely affected if we fail to maintain the applicable covenants under the agreement governing the facility. At March 31, 2004, our undrawn availability under the facility, which is calculated including outstanding letters of credit and domestic cash on hand, was $259 million, and the amount that we could borrow at that date prior to requiring the application of a financial covenant test was $109 million. We expect our undrawn availability will decrease by up to $33 million in connection with the planned appeal of an unfavorable jury verdict received on March 10, 2004, concerning litigation between our wholly-owned subsidiary TDY Industries, Inc. and the San Diego Unified Port District involving a lease of property. This matter is more fully described in our Annual Report on Form 10-K for the year ended December 31, 2003.
During the next several months, due to rising raw material prices and improving business volumes, we expect to maintain a lower domestic cash balance from 2003 year end levels, and we may borrow funds from the secured facility from time-to-time to support working capital requirements or investment opportunities. We believe that internally generated funds, current cash on hand and capacity provided from our secured credit facility will be adequate to meet our foreseeable liquidity needs.
CRITICAL ACCOUNTING POLICIES
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. In a period when raw material or other costs are extremely volatile, the use of the LIFO inventory method may result in cost of sales expense which is not indicative of cash costs during that period. In a period of rising prices, cost of sales expense is typically higher than the cash costs, and inventory as presented on the balance sheet is typically lower than it would be under most alternative costing methods.
Selling prices for the majority of our stainless products include surcharges for raw materials. These surcharges have been effective in helping to offset the impact of increased raw material costs we have experienced in the 2004 first quarter on a cash basis. The majority of raw material surcharges, which prevail throughout the stainless steel industry, are structured to recover cash costs for the raw materials incurred to produce the products shipped. For example, the surcharge for nickel, which is a significant raw material used in the production of stainless steel, is included in current month's selling price based upon the average cost for nickel as priced on the London Metals Exchange (plus a margin for handling and delivery) for the period two months prior to shipment. This two-month lag convention is used to align the cost of the raw material melted to the transaction price to the customer. While the surcharge formula is effective in recovering the cash costs for raw materials, it by design approximates the production cycle.
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. 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.
Deferred income taxes result from temporary differences in the recognition of income and expense for financial and income tax reporting purposes, or 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 (assets) or costs (liabilities) to be recognized when those temporary differences reverse. We evaluate on a quarterly basis whether, based on all available evidence, we believe that our deferred income tax assets will be realizable. Valuation allowances are established when it is estimated that it is probable (more likely than not) that the tax benefit of the deferred tax asset will not be realized. The evaluation, as prescribed by Statement of Financial Accounting Standards No. 109, "Accounting for Income Taxes," includes the consideration of all available evidence, both positive and negative, regarding historical operating results including recent years with reported losses, the estimated timing of future reversals of existing taxable temporary differences, estimated future taxable income exclusive of reversing temporary differences and carryforwards, and potential tax planning strategies which may be employed to prevent an operating loss or tax credit carryforward from expiring unused. Future realization of deferred income tax assets ultimately depends upon the existence of sufficient taxable income within the carryback, carryforward period available under tax law.
The recognition of a valuation allowance is recorded as a non-cash charge to the income tax provision with an offsetting reserve against the deferred income tax asset. Should we generate pretax losses in future periods, a tax benefit would not be recorded and the valuation allowance recorded would increase. Under these circumstances the net loss recognized and net loss per share for that period would be larger than a comparable period when a favorable tax benefit was recorded. However, tax provisions or benefits would continue to be recognized, as appropriate, on state and local taxes, and taxes related to foreign jurisdictions. The recognition of a valuation allowance does not affect our ability to utilize the deferred tax asset in the future. The valuation allowance could be reduced or increased in future years if the estimated realizability of the deferred income tax asset changes, based upon consideration of all available evidence, including changes in the carryback period available under tax law.
We have defined benefit pension plans and defined contribution plans covering substantially all of our employees. We have not made contributions to the U.S. defined benefit pension plan in the past several years. We are not required to make a contribution to the U.S. defined benefit pension plan for 2004, and, based upon current actuarial analyses and forecasts, we do not expect to be required to make cash contributions to the U.S. defined benefit pension plan for at least the next several years.
We account for our defined benefit pension plans in accordance with Statement of Financial Accounting Standards No. 87, "Employers' Accounting for Pensions" ("SFAS 87"), which requires that amounts recognized in financial statements be determined on an actuarial basis, rather than as contributions are made to the plan. A significant element in determining our pension (expense) income in accordance with SFAS 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 types of securities the plan investments are invested in, how those investments have performed historically, and expectations for how those investments will perform in the future. For 2004 and 2003, our expected return on pension plan investments is 8.75%. 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 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. Accounting principles generally accepted in the United States 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 each year, we determine the discount rate to be used to value pension plan liabilities. In accordance with SFAS 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 2003, we established a discount rate of 6.5% for valuing the pension liabilities as of the end of 2003, and for determining the pension expense for 2004. We had previously assumed a discount rate of 6.75% for 2002, which determined the 2003 expense. The effect of lowering the discount rate will increase annual pension expense by approximately $4 million in 2004. 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 SFAS 87.
Accounting standards require a minimum pension liability be recorded when the value of pension assets is less than the accumulated benefit obligation ("ABO") at the annual measurement date. As of November 30, 2003, our measurement date for pension accounting, the value of the ABO exceeded the value of pension investments by approximately $195 million. In accordance with accounting standards, the charge against stockholders' equity is adjusted in the fourth quarter to reflect the value of pension assets compared to the ABO as of the end of November. If the level of pension assets exceeds the ABO as of a future measurement date, the full charge against stockholders' equity would be reversed.
The OPEB obligation, and postretirement benefit expense recognized through March 31, 2004, does not include the expected favorable impact of the Medicare Act, which was enacted on December 8, 2003. The Medicare Act provides for a federal subsidy, with tax-free payments commencing in 2006, to sponsors of retiree health care benefits plans that provide a benefit that is at least actuarially equivalent to the benefit established by the law. Based upon estimates from our actuaries, we expect that the federal subsidy included in the law will result in a reduction in the OPEB obligation of up to $70 million. This reduction is not reflected in the financial statements or in estimates of 2004 expense because final authoritative accounting guidance regarding how the benefit is to be recognized in the financial statements is pending.
Certain of these postretirement benefits are funded using plan investments held in a VEBA trust. The expected return on plan investments is a significant element in determining postretirement benefits expenses in accordance with SFAS 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 investments are invested in, how those investments have performed historically, and expectations for how those investments will perform in the future. For 2003, as a result of a reduction in the percentage of the VEBA's private equity investments, we lowered our expected return on investments held in the VEBA trust to 9%. A 15% return on investments was assumed in prior years. This assumed long-term rate of return on investments is applied to the market value of plan investments 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. The effect of lowering the expected return on plan investments resulted in an increase in annual postretirement benefits expense of approximately $7 million for 2003. Our expected return on investments in the VEBA trust remains 9% for 2004.
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 asset's use (including any proceeds from disposition) are less than the asset's carrying value, and the asset's 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.
Goodwill is required to be reviewed annually, or more frequently if impairment indicators arise. The impairment test for goodwill is a two-step process. The first step is a comparison of the fair value of the reporting unit with its carrying amount, including goodwill. If this comparison reflects impairment, then the loss would be measured as the excess of recorded goodwill over its implied fair value. Implied fair value is the excess of the fair value of the reporting unit over the fair value of all recognized and unrecognized assets and liabilities.
A summary of other significant accounting policies is discussed in Note 1 in our Annual Report on Form 10-K for the year ended December 31, 2003.
The preparation of the financial statements in accordance with accounting principles generally accepted in the United States requires us to make judgments, estimates and assumptions regarding uncertainties that affect the reported amounts of assets and liabilities. Significant areas of uncertainty that require judgments, estimates and assumptions include the accounting for derivatives, retirement plans, income taxes, environmental and other contingencies as well as asset impairment, inventory valuation and collectibility of accounts receivable. We use historical and other information that we consider to be relevant to make these judgments and estimates. However, actual results may differ from those estimates and assumptions that are used to prepare our financial statements.
OTHER MATTERS
Intense competition and excess manufacturing capacity in the commodity stainless steel industry have resulted in reduced prices over the last few years, excluding raw material surcharges, for many of our stainless steel products. As a result of these factors, our revenues, operating results and financial condition have been and may continue to be adversely affected.
Although inflationary trends in recent years have been moderate, during the same period certain critical raw material costs, such as nickel and scrap containing iron and nickel, have been volatile. While we are able to mitigate some of the adverse impact of rising raw material costs through surcharges to customers, rapid increases in raw material costs adversely affect our results