2022 BSE SYMPOSIUM

THE EVOLUTION OF
SAFETY AT NUCOR
September 2022
 COMPANY and NUCOR
OVERVIEW

2
NUCOR TODAY
LARGEST STEEL
PRODUCER IN THE U.S.
• 28.2 million tons shipped ​to
outside customers in 2021​
• Approximately 31,000
teammates working safely at
over 300 facilities in North
America
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NORTH AMERICA’S
LARGEST RECYCLER
Nucor recycles about 20M
tons ​of scrap metal annually at
its 25 EAF steel mills​
#98 IN FORTUNE 500
• $36.5 billion in sales in
2021
• $9.4 billion ​in capital
returned to Nucor
stockholders since 2012
• NYSE listed: NUE
SUSTAINABLE STEELMAKING

Nucor’s operations
generate only a
fraction of the
greenhouse gas
emissions compared
to traditional
steelmaking
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THE NUCOR FAMILY

THE BEGINNING NUCOR GROWS: OUR FAMILY OF BRANDS

Since 1962, Nucor has grown

from a single steel joist
manufacturer in South Carolina
(Vulcraft South Carolina), to
North America’s largest
producer of steel and steel
products.

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NUCOR LOCATIONS

Nucor’s more than

300 locations
across North
America include
steelmaking, steel
products, and raw Nucor Steel
Berkeley
materials facilities.

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6
BECOMING THE WORLD’S SAFEST STEEL COMPANY

2.5

INJURY & ILLNESS RATES

2
OSHA recordables per 200,000

2.02

1.94
1.82

1.8
hours per year, 2011-2020.

1.66
1.63
1.5

1.55
1.48

1.3
1

1.1
0.5

A rate of 0.6 is considered world class and is our goal

0
2011 2012 2013 2014 2015 2016 2017 2018 2019 2020

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 Nucor Berkeley
Overview

8
NUCOR STEEL BERKELEY (CHARLESTON, SC)

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NUCOR STEEL BERKELEY BACKGROUND

Construction in 1995, production began in 1996

8,000 acre plant site including 5,000 acre conservation easement
2 x 280 ton DC EAF’s (Tap 170 short tons)
4 LMF stations (2 sets of AC electrodes)
2 tank VTD’s, 2 CSP casters and 1 Beam caster
7-Stand Hot mill, 2 pickle lines, 2 reversing mills, 1 temper mill, 1 tension level
line, batch anneal bay and a galvanizing line

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NUCOR STEEL BERKELEY BACKGROUND

975 teammates
• Safety focused culture (SC VPP member)
• Incentive based pay (Production based or Return on Assets)
• No layoff practice
• Onsite Health Clinic, Cafeteria, Gym, Credit Union, EMS team, Tuition
reimbursement, Scholarships for dependents, etc.
• 7-8% annual turnover rate (including retirements)

Over 3.6 million tons of steel produced annually

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NUCOR STEEL BERKELEY PRODUCTS

Flat Rolled Sheet and Structural Beam Steel

2,800,000 tons of Sheet Steel 800,000 tons of Structural Beam Steel

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 NUCOR Berkeley
safety journey

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SAFETY: CERTIFICATIONS & ACHIEVEMENTS

2007 – established Safety Management System and

registers to Z-10 and OSHAS 18001

2011 – recognized by SC OSHA as largest OSHA

VPP site in SC

2020 – first Nucor division to register to new ISO

45001 Safety Management Standard

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NS-BERKELEY (RECENT PERFORMANCE)
Total Case Incident Rate (TCIR) NAICS 331111

4.2
SC
3.5
STAR
2.7 National
2.4
2.1 2.2 2.1
#REF!
1.75
PSA
1.1
Linear (Berkeley)
0.77 0.66 0.6
0.45 0.35 Linear (SC)
0.12
Linear (STAR)
2018 2019 2020 2021 2022

Days Away Restricted Time (DART) NAICS 331111

Berkeley
2.4
SC
STAR
1.7
1.5 National
1.4 1.4
1.3 PSA
1.2
Linear (Berkeley)
0.7 0.65
0.51 Linear (SC)
0.27 0.28 0.27 Linear (STAR)
0.18
0
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2018 2019 2020 2021
IIR and DART Rates (Historical performance)
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15 II Rate
14 DART Rate
13
12
11
10
9
8
7
6
5
4
3
2
1
0
1996

1998

2000

2002

2004

2006

2008

2010

2012

2014

2016

2018

2020

2022
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17
100

0
20
30
40
50
60
80
90

10
70
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013
2014
2015
2016
2017
2018
DART

2019
2020
Recordable

2021
2022
RECORDABLE and DART cases (Historical performance)
RECORDABLE and DART cases (Historical performance)
100
Recordable
90
DART
80

70 During this time the culture was: “Work

hard and make tons!”
60 Safety was a program and afterthought
50 The teammate that was aggressive and
took chances, was admired and promoted
40

30

20

10

0
2005

2022
1998
1999
2000
2001
2002
2003
2004

2006
2007
2008
2009
2010
2011
2012
2013
2014
2015
2016
2017
2018
2019
2020
2021
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RECORDABLE and DART cases (Historical performance)
100
2000 – Dan DiMicco sets Recordable
90
new vision for Safety DART
80 across Nucor
70

60
2006 – Giff Daughtridge
50 becomes VP/ GM of
Berkeley – Drives
40
Personal Safety and
30 Accountability
20

10

0
2005

2022
1998
1999
2000
2001
2002
2003
2004

2006
2007
2008
2009
2010
2011
2012
2013
2014
2015
2016
2017
2018
2019
2020
2021
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LEADERSHIP AND SAFETY PROGRAM CHANGES IN THE ON-
GOING SAFETY JOURNEY
2000 – Dan DiMicco sets new vision for Safety across Nucor
2006 – Giff Daughtridge becomes VP/ GM of Berkeley – Drives Personal Safety Accountability
2007 – Berkeley establishes Safety Management System and Registers to Z-10 and OSHAS 18001
2008 – Active Teammate Participations in Safety Program / Developing Safety Champions and this is ongoing - today
2010 – Department Safety Coordinators set for Team Resource and Safety Champion Building
2011 – Berkeley Teammates recognized by SC OSHA as states largest OSHA VPP Site
2013 – John Ferriola appointed CEO and continues Drive for Safety Focus across Corporation
2014 – Berkeley re-energizes Teams approach to Safety Observations Program (STAR) 2021 – Records 54K
2020 – Leon Topalian appointed to CEO Sets new vision for Nucor to be Safest Steel Company in the World
2020 – Michael Lee becomes VP/GM of Berkeley – Continues Safety Drive and brings refreshed Vision of
Safety Expectations and Continuous improvement
2022 – Introduced a Best Mark Program on Leadership Development program Leading with Safety

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WHAT WERE THE KEY FACTORS TO IMPROVE SAFETY AT
NUCOR BERKELEY?
“We will never be able to make
Established a safety culture tons if we have to do all this
Record, track and investigate every incident - no matter how small safety stuff”
Determine root cause for the incident – Personal responsibility, defective equipment, inadequate procedures
Hold TM accountable for every incident and apply the appropriate discipline response
Ensure consistency across all departments, all managers and all supervisors
Develop a JSA for each task and job performed
2021 was not only a record
Put safety before production production year but also our
safest year ever
Plant standdowns for a recordable or serious near miss
Walk the talk – demonstrate that safety is more important than production or profit
Utilize Technology
Install cameras that cover almost all activities in the plant (> 250 cameras)
Invest in automation technology and equipment to eliminate exposure to liquid steel or other potential
hazards
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BUILDING SAFETY CHAMPIONS

Teammates accepts not only their responsibility for Safety but

for the responsibility of those around them.
Set an Example / Role Model / Demonstrate Safe Behavior
Ownership/ Personal Responsibility
Safety at Work and Safety at Home
Positive Safety Attitude with Sense of Urgency

Encourage new teammates to have the curiosity and

courage to speak up to point out safety deficiencies and
ensure that the experienced teammates have the humility to
accept the observations and suggestions

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SUSTAINING SAFETY CHAMPIONS AND CULTURE

Focus on Prevention – Attitude / Educate

Hazard Recognition / Beyond Zero

Team Effort – Observations/ Participation

Drive Involvement and Follow Up (2021 – 54,000+)

Personal Responsibility
You must be a Safety Champion

Influence others
Safety Champions drive culture, people change to environment
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CORE ELEMENTS OF OUR CULTURE

Safety is our #1 value; it is a core belief,

and it is also a condition of employment.
“”Safety first” guides everything we do
Nothing…Is more important than
SAFETY…NOTHING!
The “cowboy” or risk taker from the
early 2000’s no longer works for Nucor
– they disqualified themselves

Personal Responsibility
Responsible for those around me
Responsible for my area
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THE NUCOR BERKELEY STAR PROGRAM
It is an observation program that encourages conversations among teammates.

STAR
70000
60000 54668

50000
40000
30000
20000
10000
0
2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021

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2021 NUCOR BERKELEY’S SAFEST YEAR

Longest number of days without a recordable. 358 days (June 15, 2020 through June 7, 2021)
Largest amount of OSHA manhours without a recordable. 2.1 million manhours

Unfortunately, had 4 recordables and 2 DART cases in a 6 months period - 3 were hand injuries
Renew focus on hand safety and no-touch tools. Gloves are now required in all production areas.

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 Utilizing technology to
improve safety

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SAFETY AT THE EAF (minimizing exposure to liquid steel)

Automatic temperature takers (Robots and in-house design)

Automatic door pushers (Mo tank, KT-Grant, in-house design)
Automatic tap-hole sanders (Aldo Longo, in-house design)
Automatic plunger
Automatic tap-hole cleaner
Inspection cameras
Shielded walkways and fences around the EAF

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AUTOMATIC TEMPERATURE TAKERS

Video

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PROTECTIVE TUNNELS

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Fencing

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Guarding and Handrails

Recently reinstalled aluminium swing guarding in

annealing bay – a issue in the past with steel
guarding and the overhead crane magnet –(intern
idea and project) – so we get everyone involved
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EAF INSPECTION CAMERAS

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IR FLIR EAF INSPECTION CAMERAS (East and West)

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IR FLIR EAF INSPECTION CAMERAS (Cave in video)

Video

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IR FLIR EAF INSPECTION CAMERAS (Roof Leak Video)

Video

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TAPHOLE PLUNGER

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TAP HOLE SANDERS

Video

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AUTOMATIC DOOR PUSHERS

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Pulpits and Workstations

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TAPPING CAMERA

Operator can see actual level in the ladle.

Improves tapping consistency for heel control and quality.

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EAF BURN-OPEN TECHNOLOGY EVOLUTION

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EAF TAP HOLE CLEANING (BSE THM)

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Video
AUTOMATIC TEMPERATURE TAKERS (LMF)

Video

44 Video
AUTOMATIC TEMPERATURE TAKERS (Stir Station)

Video
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AUTOMATIC TEMPERATURE TAKERS (Stir Station)

Video
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LADLE STIR CAMERAS

Video
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MISCELANEOUS TECHNOLOGY: BROKK 120D

• Worlds smallest diesel driven demolition robot

• Small enough to put inside Degas tanks
• Several places around the Melt Shop where we will utilize this machine

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REFRACTORY LASER

Video

The ladle scan takes approximately 2 minutes

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IMAGE OF SCAN

Displayed in the Lmf pulpit and at the ladle wall when the scan is complete.

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SCAN RESULTS

This scan of ladle 16 showed a thin spot (1.32”) in the slag line. The same ladle 2 heats
prior showed 3.56” in the same spot. We tapped into this ladle and immediately had a hot
spot on the outside of the ladle.
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INFRARED CAMERA ALARMS IN PULPIT IF A RAPID RISE IS DETECTED.

..

A rapid rise alarm was received just after killing this heat. The operator must turn the
stir off and visually inspect the outside of the ladle. After visually verifying the alarm
was a hot spot this heat was re-ladled.
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AFTER RE-LADLING HEAT

53 Brick missing in slag line

BURN-OPEN AT THE CASTER
Burn-open robot to
J Lance be installed

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SAFETY WITH PRODUCT HANDLING (minimizing forklifts and
cranes moving coils around)

55 Video
WHY WE WORK SAFE

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CONTACT INFORMATION:

Presented by Eugene Pretorius eugene.Pretorius@nucor.com

Manager of Steelmaking Technology

For specific safety questions please contact:

Scott Hatchell scott.hatchell@nucor.com
Nucor Berkeley Safety Director

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