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00:00
I'm dick Wardrop chairman and chief
executive officer of a case deal you are
about to see some of the most awesome
sights you will ever witness the making
of Steel it's hard to imagine what our
lives would be like without this
versatile material and even though steel
is part of our daily lives it is easy to
overlook the thousands of ways we depend
on steel around the world and even
beyond our planet in space from the time
you wake until your day is done steel
was working to make your life safer
00:31
stronger and better just think for a
moment of how steel helps you every day
the steel that supports homes and
schools and skyscrapers and bridges
roads and dams the steel that forms such
essential modern conveniences like
washers dryers stoves and refrigerators
the steel that makes your car safe and
dependable for years the development of
large-scale steel production in nearly
150 years ago provided the single most
important milestone in a worldwide
01:02
industrial revolution as we approach the
21st century steel continues to
revolutionize the way we live from the
bolts that secure rocket boosters to the
space shuttle to ultra light and strong
automobile bodies steel is what the
future is made of what other material
brings all these benefits to our lives
and does so as the most recycled
material in North America more steel is
recycled than aluminum paper plastic and
glass combined now you might think that
01:35
a product that can do all these things
would be quite expensive well here's
another surprise from this incredible
material in fact a bond of Steel costs
less today in a pond of butter or
potatoes today's steel industry and a.k
steel in particular utilizes some of the
most advanced computer controlled
equipment in the world to produce the
highest quality products so I hope you
enjoy this brief glimpse at how we make
this incredible material an ache a steel
and I think you will agree that it is a
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fascinating process
on a journey from the dark reaches of
the universe a meteorite hurtles through
space nearing the earth gravity pulls it
through the atmosphere the mass explodes
under the strain
raining bits of rock and iron on the
ground following the streaking flight
the heavenly metal is recovered the
strange material is fashioned into a
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primitive tool fantasy perhaps or does
it explain as many think why in ancient
languages the word steel means star
metal we do know that man has used
heavenly and earthly iron for thousands
of years in a time and place unrecorded
came the discovery that iron could be
made better stronger and even more
useful a pinch of nickel a dash of
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manganese dislodge a bit of carbon the
alloy steel was discovered the age of
alchemy gave birth to the science of
metallurgy in 1856 a process for making
steel on a grand scale was discovered
and a tremendous Industrial Revolution
was born 150 years later the evolution
of new and better steels continues to
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unfold at a K steel it all begins as it
has for centuries by assembling the
essential ingredients in northern
Minnesota miners coax or from the rocky
veins of the Mesabi Range straight from
the ground this taconite is unsuited for
a K Steel's productive blast furnaces
pulverized and concentrated the iron ore
is fused back to
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as marble-sized pellets steel rails will
guide the ore to its final destination
at the base of a que Steel's blast
furnaces 600 miles away under the hills
of West Virginia miners dispatched tons
of coal to the surface it travels by
rail to a case seals plants where it
will become the primary fuel in the 4000
degree Inferno needed to reduce the ore
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to molten iron before the coal can begin
the demanding task of smelting iron it
must be transformed into a more
efficient form called coke the process
begins by loading a blend of coals into
a series of tall narrow ovens the ovens
are sealed from the air to prevent the
coal from burning away in the 2400
degree temperature
after baking for nearly a day a 12-ton
volcano of coke is pushed from the oven
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into an awaiting railcar reunited with
oxygen the coke ignites in a scorching
dance like charcoal the coke is now
light porous and strong a nine thousand
gallon cold shower tempers the heated
passion of the coke sending a billowing
plume of steam skyward completing the
raw material list is limestone mined
from quarries throughout the Midwest
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this natural cleansing agent will
collect the impurities released from the
coke and/or West Virginia coal limestone
from Kentucky taconite from Minnesota
and a pinch of high-grade iron from
South America these earthly ingredients
will ascend 20 stories to meet in the
iron makers colossal VAT skip cars halt
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they're carefully measured burden up the
steep incline delivering a steady supply
of fuel and/or to the furnace a pair of
valves called bells allow the raw
materials to enter the furnace without
releasing the pressure of hot air and
gases in the furnace to our metallurgist
this giant structure is known as a
counter-current packed bed thermal
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chemical pressure vessel but simply the
blast furnace is named for its most
indispensable ingredient a blast of air
and gas hot enough to ignite the coke
stoves heat the air to nearly 2,000
degrees turbo engines propel the hot air
at nearly 200 mile
per hour into the furnace through
openings called Twitter's the poorest
coke allows the hot wind to penetrate
the raw materials and heat the or oxygen
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reacts chemically with the coke creating
a reducing atmosphere this thermo
chemical process creates temperatures of
more than 4,000 degrees under this
intense Inferno the ore releases molten
iron which drips to the bottom of the
furnace gases from the reaction are
cleaned and recycled as fuel for the
coke ovens and blast furnace stoves the
limestone traps impurities released from
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the burning coke and or becoming a slag
which floats atop the heavier molten
iron the iron and slag flows almost
continuously from two tap holes near the
bottom of the furnace a drill pierces
the clay plug of the tap hole and bores
into the heart of the furnace a 2,700
degree river of molten iron is born from
the belly of the furnace in a
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spectacular display of man's command of
nature unleashed the fiery tide follows
its directed course beneath the watchful
eyes of its creators with respect for
its fury the quality of the metal is
monitored and recorded the limestone
having performed its cleansing job rides
out of the furnace atop the river of
iron
diverted to a cooling pit it will be
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recycled perhaps as the bed of a new
highway or railroad borne of brittle
brute strength the iron is destined for
refining school where it will learn to
be rolled drawn and stretched as steel
bearing more than 200 tons each
torpedo cars haul the molten iron to the
basic oxygen furnace where it will
complete its transformation into steel
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poured into a ladle the iron is treated
and skimmed to remove slag containing
sulfur an impurity left over from the
coke in the blast furnace while the iron
is being skimmed scrap steel recycled
from elsewhere in the mill is loaded
into the furnace cleanse of sulfur the
molten iron is poured into the mouth of
the furnace in a pulpit 200 feet from
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the fiery metal the furnace is rocked
stirred and monitored with
computer-assisted precision high purity
oxygen is blown into the furnace at
supersonic speed through a water-cooled
lance like a giant cutting torch the
oxygen Lance raises the temperature of
the iron to nearly 3,000 degrees burning
off yet more impurities in the iron and
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melting the scrap in some 20 minutes the
rage of the furnace subsides having
tamed the ions brittle strength rid of
excess carbon phosphorus and silicon the
medal has newfound power
Steele is born
having harnessed the energy of the Sun
itself
aka Steel's metallurgical chefs keeps
entry of their bubbling recipe a sample
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from the molten bath is retrieved in the
shops metallurgical lab quality control
technicians analyze and record the
composition of the metal before it
solidifies final adjustments are made to
the chemistry a vacuum degassing removes
additional carbon this allows the seal
to be drawn and shaped into such
products as automotive parts special
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alloys titanium aluminum and manganese
among others had special qualities for
hundreds of different uses a lid
insulates the molten brew during casting
capable of lifting the weight of nearly
200 cars the crane operators delicate
touch placed the ladle four stories high
atop the caster a gate is opened at the
bottom of the ladle liquid steel flows
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through a shroud into a trough called
a tundish at a rate of five tons per
minute nozzles in the bottom of the
tundish directs the steel into
water-cooled moulds as the steel flows
into the molds it begins to solidify
still soft the steel is gently directed
by the curved radius of the caster to a
horizontal position at the run-out table
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from molten steel slabs emerge glowing
from an internal temperature of nearly
2,000 degrees automatic torches embrace
the slabs burning through the steel
which is now nine inches thick a tag is
attached to record the slabs identity as
the steel is processed into the
customer's order still about 1,200
degrees the slabs are cool enough to
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load on rail cars for their journey to
the hot strip mill more than 30 feet
long each slab weighs nearly 90,000
pounds with enough energy to heat a city
the slabs are bathed in a glowing
furnace for three hours shielded from
the 2400 degree heat of the slab an
operator sends the monolith toward its
destination more than half a mile away
the slabs glow and unmistakable
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footsteps down the row line are familiar
science at the hot strip
in six minutes this 40-ton behemoth will
make the most awesome transformation in
steelmaking as more than 130 thousand
horsepower press it as thin as a
computer disk the bar is squeezed
between the huge roughing mill rolls
like so much clay blasts of water break
away the thin crusts of scale that
15:05
formed on the slab during heating
sending up a rooster tail of spray the
hot steel yields to the relentless
hydraulic pressure in the only manner it
can halfway to its destination its nine
inch girth has been trimmed to a mere
inch and a half
the rest of its mass now trails along
more than a hundred feet behind its
front edge
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linked by a host of computers and radios
operators at the hot strip monitor every
facet of the process some of the most
advanced technology in the world
controls the seven finishing stands of
the hot strip mill only several feet
apart these massive rolls give the strip
its final thickness and shape as the
seal passes through each stand its
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thickness is reduced further by the time
the front edge of the strip clears the
final stand it may be traveling more
than 25 miles per hour
a half mile from its blistering-hot
start a cold spray cools the steel as it
speeds toward the coil errs these
marvels of timing catch the speeding
strip and wind it into a coil from
glowing slab to glistening strip what
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was minutes ago a mere 30 feet long this
coil would now span a dozen football
feet but the journey for this aka seal
is far from over
this hot rolled coil now has the
fundamental strengths of seal to meet
the sophisticated requirements of many a
case steel customers these green coils
as they are called will be further
processed at the cold strip mill at the
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pickling complex a mild bath of
hydrochloric acid removes the oxide it
had formed during the steels journey
through the hot strip mill following a
rinse and a dry the steel is again wound
into a coil and coated with an oil to
prevent rust and prepare it for rolling
on the cold mill in its basic operation
the cold mill functions much like the
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hot strip mill squeezing the steel with
tremendous hydraulic force to reduce its
thickness but as the name implies no
heat is applied in the cold bill this
creates a smooth finish and increases
the strength of the seal
although the steel isn't heated friction
from 2400 tons of pressure readily
vaporizes the mills coolant as the strip
speeds from stand to stand at 60 miles
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per hour the mill rolls costing up to
70,000 dollars each are changed every
few hours to ensure consistent quality
aka seals trained operators have made
this the most productive cold mill in
the world
producing some of the highest quality
steel available coils are inspected for
the slightest blemish and thoroughly
tested for all quality characteristics
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for some customers cold rolled steel
meets their requirements exactly its
thickness has been reduced from that of
a computer disk to a credit card the
surface is smooth and the steel has
gained strength in the cold rolling
process for the most demanding uses
however additional processing will give
the steel its final characteristics at
the zinc grip line cold rolled steel is
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immersed in a bath of molten zinc this
hot dip galvanizing process wraps the
steel in a pure zinc rust resistant
coating automakers and other customers
depend on aka seals industry leadership
in steel technology for superior coated
steels these advanced materials help
automakers build cars with extended
warranties against rust and corrosion
aluminum coated cold rolled steel
19:52
enable the makers of automotive exhaust
systems to build mufflers tailpipes and
resonators which lasts the lifetime of
car if not longer aluminized steel is
ideal for making furnaces and other
heat-resistant products
culverts and other drainage products
fabricated from this aluminum coated
steel offer decades of service built to
meet the needs for better automotive
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Steel's the electric galvanizing line
plates cold rolled steel
electrolytically using the steel itself
as a conductor coatings of pure zinc and
a zinc nickel combination and here to
the strip in a giant 2,000,000 amp
electrical circuit electro galvanized
seals are preferred for their uniform
finish providing strong smooth fenders
hoods and other automotive body parts
20:54
for nearly 100 years a ke Steel's
Middletown Works has been home to some
of the most innovative thought and
dedicated steel makers in the world
along the way a few of our neighbors
have found our Midwestern hospitality
quite to their liking as well on the
banks of the Ohio River in Ashland
Kentucky a case steals metallurgical
expertise and hospitality are equally
21:27
evident in the Bluegrass State we even
gave our blast furnace a personality by
fondly naming her Amanda the largest of
her kind in the world when she was built
Amanda just seems to get better with age
day and
Amanda feeds a steady diet of molten
iron to Ashland steelmaking shop and
it's a good thing too because the
continuous caster at Ashland has the
healthiest appetite in the world for
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steel built to produce steel for pipe
this caster was actually mothballed a
few years ago when the need for oil and
gas pipe all but disappeared redesigned
for slabs the men and women of a case
steel breathed new life into the machine
and never looked back they've given new
meaning to the term continuous casting
by setting world records with regularity
in what resembles a chess move designed
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for giants a new heat of Steel is traded
for the empty ladle the tundish still
full of molten steel continues to feed
the caster during the ladle change each
day Ashland's bounty of slabs embarks on
an open-air train headed for middle town
where they will help to satisfy the
hunger of the hot strip mill on the
return trip Middletown will send coils
to supply Ashton's hot dip galvanizing
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and Galvan Ealing line fed by the
Middletown cold mill Ashland's versatile
coating line produces both galvanized
and galvan ield steels a process that
alloys the zinc coating into the base
metal for high quality automotive steels
400 miles down the Ohio River from
Ashland the most remarkable steel
facility in the world is springing to
life near Rockport Indiana
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aka seals rockport works will feature
one of the widest most powerful and by
far the most productive cold Mill in the
world
a massive sixty thousand horsepower mill
it will utilize some of the most
advanced quality control and mill design
in the world it will produce carbon and
stainless steels allowing a que to serve
additional customers in the automotive
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and food and chemical processing markets
Rockport's hot dip line will use a case
steels legendary coating technology to
produce the widest product available for
the most demanding automotive customer
requirements innovative pickling
annealing and tempering facilities will
complete the state-of-the-art addition
to a case seals world-class facilities
rockport will join middletown and
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Ashland works in a leap in the 21st
century steel making meeting the needs
of its discriminating customers the
employees of ak's steel blend the
heritage of steel making artistry with
technology on the frontier of tomorrow
coaxed from its humble earthly origins
and transformed the glistening metal
steel is the fabric of our future for
more than 85 years this versatile metal
25:19
has formed the foundation of modern life
shaping the cars and trucks of tomorrow
steel is meeting the challenge for
lighter stronger and more
versatile components completely
recyclable but designed to last at home
steel provides comfort and convenience
in virtually every room even in the very
walls that shelter us from nature's rage
so what does the future hold for this
adaptable metal with a distinguished
25:50
past at ak's steel there is plenty of
evidence to suggest the brightest days
for steel have yet to be seen
nearly 6,000 dedicated men and women
have their hands and their minds on the
most productive equipment in the world
for all its fiery origin and brute
strength steelmaking is a venture of the
mind and every day those Minds gaze into
this metal soul and ask silently what if
27:15
we're very pleased with the formability
results we got on this spender and this
is using England's baked hardenable
steels this is our to say eg baked
Cardinal off the continuous in the align
you know no if we look at this data most
of this material safely meets the core
lies guarantee let me just discuss with
you the benefits that we see the I
inspect product has many attributes that
we've looked at heat treated Franks in
order to get the strength of with micro
alloy making approach more uniform needs
you to machine I think my Corelli is
27:46
definitely a candidate for this Bob
we've been able to identify that we have
the capacity available to not only the
Rho B but the normalizer as well I'll
make sure that was an access point we're
the experts on carbon and still making
so they're looking for us to bring this
together this part is very similar to
some of the designs that could be
manufactured three years from now this
whole quantity squared divided by the
stiffest actor eelain's been market
driven for years now and today our
intent is to find relationships
28:18
partnerships with our customers so we
can satisfy their needs in fact exceed
their needs and we'll do it through
technology and our people by working
well in advance of that customers
production we can anticipate their
future needs and satisfy those needs
with steel with inland steel
steam from inland the process of
manufacturing that steel fulfilling the
customers needs begins right here in
29:04
America's industrial heartland East
Chicago Indiana at England's Indiana
Harbor works it's one steelmaking plant
since the Indiana Harbor Works opened in
1902 the plant has grown from 50 acres
to more than 1,900 acres producing more
than 6 million tons of steel a year but
the plants dramatic growth hasn't been
in size alone steelmaking and steel
29:34
makers have gone high-tech in every
phase of the steelmaking process
extensive research and development from
the latest and computer-aided design and
testing to advanced computer automated
process control
making iron the first step in producing
steel used to be a relatively simple
process of mining or coal and limestone
and then smelting the mixture at
extremely high temperatures into molten
iron
today's specialty steel products demand
a critical level of purity only
30:14
achievable through advanced materials
technology technology to efficiently
mine abundant low-grade ore crushes
magnetically separate the iron bearing
particles form the iron into pellets and
bake them hard the end result I you nor
that's actually purer than the old
natural lords England's technology goes
one step further
baking limestone a purifying agent
called a flux into the or producing
30:46
fluxed pellets the raw materials move to
inland Indiana Harbor works in special
rail cars and giant ore vessels these
ships which carry up to 60,000 tons of
pellets in a single trip ourself
unnoticed capable of discharging their
cargoes quickly and continuously while
the fluxed pellets arrive at inland
ready to use coal the indispensable fuel
necessary for iron making must be
further refined and purified into coke
31:17
before it will burn hot enough to make
iron coking eliminates unwanted tar and
gases by heat refining the coal
long vertical batteries of coking of ins
the cool is first charged into the
individual ovens after baking the
finished coke is pushed from the oven
into a quench car in water cool
the coke then moves by conveyor to the
blast furnace for steelmaking begins
among England's nine blast furnaces is
31:53
the largest and most advanced iron maker
in the Western Hemisphere towering more
than three hundred feet high this single
blast furnace can produce more than
9,500 tons of pure molten iron a day
more than the combined output of five
smaller furnaces to make quality steel
you have to make quality iron and we
make sure that's what comes out of this
furnace Computers monitor every stage of
the process from the precise quantity of
32:24
raw materials charged into the furnace
to the exact chemistry and temperature
of the hot metal in one continuous
process the coke and fluxed pellets are
conveyor charged into the furnace and
blasted with superheated air in natural
gas up to 3,000 degrees Fahrenheit the
intense heat melts the limestone in the
fluxed pellets the limestone combines
with impurities in the iron to form slag
which then floats to the surface of the
molten
33:00
separated from the slag the molten iron
is tapped from the bottom of the furnace
running through troughs into specially
lined to ladle cars
the basic oxygen furnace is or BOF s can
produce a heat or batch of more than 200
tons of prime steel in about 35 to 50
minutes here begins the intricate
process of refining the iron into
custom-tailored steel making steel has
been a position in my family my father
33:53
and my grandfather both work
they never Trevor
basically steel is iron refined for
added for mobility and strength
approximately 90 tons of scrap recycled
steel are charged into the furnace along
with 200 tons of diesel rise iron
alloys are added to give the Steel's
special properties a supersonic blast of
pure oxygen is blown into the furnace
producing a powerful chemical reaction
34:41
at temperatures above 3000 degrees
defining the iron and scrap mixture into
molten steel each individual heat is
tailored to the customer's exact
specifications some customers need ultra
pure low carbon steel for finer surface
quality and for mobility to achieve
those standards the steel is tapped from
the BOF and further refined in a process
called ladle metallurgy
35:19
each of inland steelmaking shops has its
own ladle met processing facilities
powdered chemicals alloys and D sulfur
izing agents are added to the steel to
achieve the customer specific
metallurgical for mobility
characteristics to ensure maximum
control over the Steel's final chemistry
England uses vacuum degassing a special
ladle metallurgy process that siphons
35:50
the molten steel into a degassing vessel
where unwanted carbon and other
impurities are removed as the steel
flows up one snorkel and back into the
ladle through the second snorkel alloys
are added to the ultra clean steel in an
oxygen-free environment vacuum degassing
produces clean ultra low carbon steels
that customers can form into complex
shapes previously unattainable it also
assured superior quality for electrical
36:20
Steel's used in high efficiency motors
fine-tune the molten steel is ready for
shaping in one of England's for
continuous casters which turn out slabs
blooms and billets continuous casting
enhances quality conserves energy and
boosts productivity in yield the
computers monitor the hundreds of
variables in the process and quickly
make any adjustments necessary to meet
the spec
the molten steel flows into the caster's
water-cooled mold or it begins to
36:54
solidify and take shape The Strand of
hot steel moves through a long automated
series of horizontal and vertical rules
which carefully shape it air in water
sprays slowly cool the steel
the Slavs rules and billets are cut to
length and transported for shaping and
finishing at England's rolling mills
this nine inch thick slab is about to be
rolled into a 3,500 foot long coil of
hot rolled sheet steel the process
37:42
begins by reheating the slab to 2300
degrees for approximately three hours
today is customer surface quality
standards will not tolerate even the
smallest blemish that's why we have
these walking beam furnaces so to give
it a kid grub treatment take the slab
and put it on the line without as much
as a scratch
from here a series of automated roughing
and finishing stands stretching more
than half a mile long roll the slab into
38:22
sheet steel
gentle water remove surface scales on
the steel as it moves through the
rolling stands
eleven wastewater recycling systems
purify the water used in this and other
processes at the plant
sensing devices continuously transmit
the slabs thickness width temperature
and squeezing force of the rolls to a
computer which instantaneously makes the
adjustments necessary to ensure the coil
specs in just four minutes that nine
39:04
inch thick slab is rolled into a coil of
sheet steel half a mile long and is thin
as a dime hot rolled sheet is the ideal
material for products such as pipe and
tubing Auto frames rail cars and
construction and agricultural equipment
however other products such as exposed
automotive body parts appliance cabinets
office furniture and electric motors
require a smoother surface finish more
precise thickness and other mechanical
39:35
properties to achieve those qualities
the hot rolled coil is cold rolled at
one of England's cold rolling mills the
coil is first treated to a hot acid bath
called pickling to remove any surface
oxides
then without reheating the coil is cold
rolled in a tandem mill but tremendous
pressure reduces the Steel's thickness
since cold rolling hardens the steel a
heat treating process called annealing
40:10
is used to restore for mobility
there are two ways to anneal steel in
batch annealing the coils are slowly
reheated for five days in large furnaces
where careful temperature control
produces the precise combination of
strength and for mobility using our
advanced continuous annealing process
Ayman reduces that annealing time to
less than 10 minutes the cold rolled
steel enters the line and after cleaning
40:42
move through a succession of heating and
cooling processes that lock in the metal
structure and strength
this line simply is a high-speed waiting
for
we have the ability on this line
who are very accurate
the product
once a meal the steel is lightly cold
the temperament to improve its shape
surface and mechanical properties
England's Indiana Harbor works produces
world-class cold rolled sheet steel but
41:23
here in new carlisle indiana inland and
nippon steel corporation have invested
one-half billion dollars to build a ntek
the world's most advanced continuous
rolling mill i Antec combines five
previous steps into one pickling tandem
rolling annealing temporal in an
inspection our continuous automatic line
produces in less than one hour what
traditionally took 12 days i in tech
41:54
produces the best full rolled sheet
steel in the world increasingly today's
customers are requiring cold rolled
sheet steel with the highest corrosion
and heat resistance properties to
satisfy specific customer needs inland
galvanizes or aluminized as the steel
hot dip galvanizing passes the steel
through a bath of molten zinc while
electro galvanizing applies the zinc
coating electrolytically both processes
42:25
offer superior corrosion resistance
aluminized coating the steel with
aluminum provides both heat and
corrosion resistance in addition to
sheet steel inland produces a full line
of plate bar and structural steel plates
are flat rolled products that are
thicker than sheet for greater strength
structural shapes include the wide
flange and eye beams used in building
and bridge construction today as a
result of continued investment in
42:57
research inland leads the nation in the
production of special quality bar
products
the park reduction process often begins
in England's electric furnace
steelmaking shop other big advantages of
Steel is that we can recycle our two
electric furnaces we use the charge is
virtually 100% scrap
large amounts of carefully selected
scrap are charged into the electric
furnace
giant electrodes are then lowered into
the chamber and in two hours the intense
43:51
heat produced by the arcing between the
electrodes and scrap melts it into
molten steel
once the steam is tapped from the
electric furnace it moves to the ladle
metallurgy station for fine tuning and
then on to be continuously cast into
semi-finished billets which are reheated
and rolled into a variety of bar
products including round squares and
hexagons
some bar users however require steel
with metallurgical properties that only
44:36
a basic oxygen furnace can impart that
steel is then rolled into billets which
are then reheated and rolled into
finished bars
it's impressive watching iron ore and
cold and limestone become steel and it's
easy to get carried away with the
technology and the machinery and work
here but it takes more than technology
to make steel it takes people people who
are committed to knowing the needs of
our customers and doing whatever they
have to do to satisfy those needs
45:08
it takes a company committed to hiring
and nurturing the right people and
providing them with the best technology
in the world for their work
the people abandoned steal understand
their role in commitment whether the
final product is an automobile an
appliance an electric motor a piece of
heavy equipment construction materials
or whatever the product may be it starts
with them and high quality steel steel
45:46
from England
you
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