Nucor Steel Decatur has awarded Primetals Technologies a contract to modernize its continuous thin-slab caster at its manufacturing facility in Decatur, Alabama. The project represents a significant investment in advanced steel production technology and is aimed at improving equipment reliability, product quality, and long-term operational performance.
The comprehensive upgrade will replace existing caster segments with newly engineered, wider frames featuring enhanced structural strength and optimized secondary cooling spray patterns. The redesigned equipment is intended to support current production requirements while creating a platform for future process improvements, including the implementation of dynamic soft-core reduction technology to enhance the internal quality of steel products.
The modernization marks an important milestone for both companies, as it will be the first continuous thin-slab caster designed by Primetals Technologies for Nucor Corporation. All major manufacturing, assembly, testing, and commissioning activities for the project will be carried out in Alabama, highlighting the commitment to local production and engineering expertise.
Under the agreement, Primetals Technologies will supply new benders, caster segments, and a comprehensive inventory of critical spare components over the next three years. The package includes rollers, hydraulic cylinders, and spray nozzles designed to support uninterrupted operations and improve equipment availability throughout the production lifecycle.
In addition to supplying new equipment, Primetals Technologies will provide complete engineering services covering machine design, structural analysis, roller assemblies, support systems, and secondary cooling optimization. The project scope also includes the installation of two new strand checking systems and a dedicated lifting device to improve operational efficiency and maintenance procedures. The companies will continue their existing long-term maintenance partnership, with Primetals Technologies providing ongoing technical support and maintenance services to maximize equipment reliability, operational performance, and service life.
One of the most significant engineering enhancements involves upgrading the caster from a two-roller configuration to a three-roller design. This modification is expected to increase bearing capacity by approximately 50 percent, creating a more robust and durable operating system capable of supporting demanding production conditions. The new frames will also be manufactured using marine-grade materials, offering improved resistance to corrosion and extending the operational lifespan of the equipment.
Nucor Steel Decatur is one of the primary flat-rolled steel manufacturing divisions of Nucor Corporation and produces a broad range of carbon steel sheet products, including hot-rolled, pickled, cold-rolled, galvanized, and galvannealed steel for customers across multiple industries. The company’s Alabama operations produce more than three million tons of sheet steel annually, supplying critical sectors such as infrastructure, energy, transportation, and construction. The latest investment underscores Nucor’s continued commitment to strengthening its manufacturing capabilities while supporting the long-term growth of the U.S. steel industry.
