U.S. Steel Gary Works

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U.S. Steel Gary Works, also known as U.S. Steel Gary, is a steel plant in Gary, Indiana, United States that operates basic oxygen furnace (BOF) and blast furnace (BF) technology.

Location

The map below shows the exact location of the plant in Gary, Indiana, United States:

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  • Location: Gary Works, One North Broadway, Gary, Indiana 46402, United States
  • Coordinates (WGS 84): 41.620799, -87.348266 (exact)

Background

The U.S. Steel Gary Works steel plant began operating in 1908 after beginning construction in 1906. For many years, the Gary Works was the world's largest steel mill. It is currently the largest U. S. Steel manufacturing plant; its products are used for the automotive, metal building components, home construction and appliance markets.[1]

In 2018, U.S. Steel announced it would invest a minimum of $750 million into modernizing and enhancing Gary Works.[2]

In October 2021, U.S. Steel announced plans to install more pig iron capacity at the Gary Works plant, a project which would be completed in 2023.[3]

In late 2021, the Gary Works plants announced it would be idling two of its blast furnaces for a few weeks to make improvements.[4]

Following the finalization of the merger between Nippon Steel Corporation and U.S. Steel in June 2025, the facility became the centerpiece of an $11 billion domestic investment commitment. As part of this strategic partnership, U.S. Steel approved a $350 million project in December 2025 to fully reline Blast Furnace #14, a investment intended to extend the unit's operational life by up to 20 years.

Environmental Compliance

In 1998, the EPA and U.S. Steel agreed that Gary Works would clean-up its facility, as the site was contaminated with metals, volatile and semi volatile organic compounds, and PCBs. As of 2005, the EPA lists that U.S. Steel has completed several interim measures, such as excavating contaminated soil.[5]

In 2016, the EPA fined U.S. Steel $2.2 million for pollution at several of its facilities, including Gary Works. The company also committed to spending $800,000 removing contaminated transformers at its Zug Island and Gary facilities.[6][7]

Ownership Tree

This ownership tree is part of the Global Energy Ownership Tracker, a project of Global Energy Monitor.

Low-emissions/green steelmaking

This steel plant is associated with a green steel project tracked in the Green Steel Tracker. Details about the project are included below.

Table 1: Green Steel Project Details

All references for the above data are available in the Green Steel Tracker.
Project 1
Project name United States Steel Gary Works CCS
Company United States Steel Corporation
Company has climate goals? Yes
Location Indiana, United States
Project website Not available
Project scale Demo
Project status Construction
Technology to be used CCS for BF-BOF
Technology details CarbonFree SkyCycle
Iron production capacity (million tonnes per year) Not applicable
Steel production capacity (million tonnes per year) Not applicable
CO2 capture (million tonnes CO2 per year) 0.05
Hydrogen generation capacity (MW) Not applicable
Investment size (m USD) Not stated
Partners CarbonFree
Date of announcement 4/23/2024

Plant Details

Table 2: General Plant Details

Start date Workforce size
1908[8] 2246[9]

Table 3: Ownership and Parent Company Information

Parent company Parent company PermID Parent GEM entity ID Owner Owner company PermID Owner GEM entity ID
Nippon Steel Corp [100.0%] 4295877313 [100.0%] E100000000652 [100.0%] United States Steel Corp [100%][10] 4295903049 E100000001319 [100%]

Table 4: Process and Products

Steel product category Steel products Steel sector end users ISO 14001 Main production equipment
semi-finished, finished rolled[10] sheet, plate, hot rolled, cold rolled, galvanized sheet, tinplate, pig iron[10] automotive, building and infrastructure, steel packaging[10] 2022[11] BF; BOF

Table 5: Plant-level Crude Steel Production Capacities (thousand tonnes per annum)

1Please see our Frequently Asked Questions page for an explanation of the different capacity operating statuses.
Capacity operating status1 Basic oxygen furnace steelmaking capacity Nominal crude steel capacity (total)
operating 7800[12] 7800[12]

Table 6: Plant-level Crude Iron Production Capacities (thousand tonnes per annum)

1Please see our Frequently Asked Questions page for an explanation of the different capacity operating statuses.
Capacity operating status1 Blast furnace capacity Nominal iron capacity (total)
operating 6495[13][14][15] 6495[13][14][15]

Table 7: Upstream Products Production Capacities (thousand tonnes per annum)

Sinter Pellets
4400[16][17] NF

Table 8: Actual Plant-level Crude Steel Production by Year (thousand tonnes per annum)

Year BOF production Other/unknown steel production Total (all routes)
2019 unknown unknown –
2020 unknown unknown –
2021 4524[18] –[18] 4524[18]
2022 5226[18] –[18] 5226[18]
2023 5325[19] –[19] 5325[19]
2024 4914[20] –[20] 4914[20]

Table 9: Actual Plant-level Crude Iron Production by Year (thousand tonnes per annum)

Year BF production Total (all routes)
2019 4307[21] 4307[21]
2020 3965[22] 3965[22]
2021 4980[23] 4980[23]
2022 4900[24] 4900[24]
2023 5200[25] 5200[25]
2024 5400[26] 5400[26]

Unit Details

Table 10: Blast Furnace Details

Unit name Status Start date Furnace manufacturer and model Current size Current capacity (ttpa) Decarbonization technology Most recent relining
BF 14 operating[13] 1974[27] Saint-Gobain (parts)[28] 3244.0[25] 2540[13] On April 3, 2024, US Steel Corporation and CarbonFree signed an agreement to implement CarbonFree’s SkyCycle™ technology at U.S. Steel’s Gary Works Blast Furnaces. This innovative project will capture and mineralize up to 50,000 metric tons of carbon dioxide annually, marking a significant step in carbon capture efforts.[29] 2026-09[30]
BF 4 operating[31] 1917[32] – 1496.0 m3[24] 1360[14] On April 3, 2024, US Steel Corporation and CarbonFree signed an agreement to implement CarbonFree’s SkyCycle™ technology at U.S. Steel’s Gary Works Blast Furnaces. This innovative project will capture and mineralize up to 50,000 metric tons of carbon dioxide annually, marking a significant step in carbon capture efforts.[29] 2020[33]
BF 6 operating[14] 1910[32] – 1506.0 m3[24] 1234[14] On April 3, 2024, US Steel Corporation and CarbonFree signed an agreement to implement CarbonFree’s SkyCycle™ technology at U.S. Steel’s Gary Works Blast Furnaces. This innovative project will capture and mineralize up to 50,000 metric tons of carbon dioxide annually, marking a significant step in carbon capture efforts.[29] 2018[34]
BF 8 operating[35] 1909[32] Saint-Gobain (parts)[28] 1299.0 m3[24] 1361[15] On April 3, 2024, US Steel Corporation and CarbonFree signed an agreement to implement CarbonFree’s SkyCycle™ technology at U.S. Steel’s Gary Works Blast Furnaces. This innovative project will capture and mineralize up to 50,000 metric tons of carbon dioxide annually, marking a significant step in carbon capture efforts.[29] 2016[36]

Table 11: Basic Oxygen Furnace Details

Unit name Status Start date Current capacity (ttpa)
unknown BOF (1) operating[12] 1965[37] 1300[12]
unknown BOF (2) operating[12] 1965[37] 1300[12]
unknown BOF (3) operating[12] 1965[37] 1300[12]
unknown BOF (4) operating[12] 1973[37] 1300[12]
unknown BOF (5) operating[12] 1973[37] 1300[12]
unknown BOF (6) operating[12] 1973[37] 1300[12]

Articles and Resources

Additional data

To access additional data, including an interactive map of steel plants, a downloadable dataset, and summary data, please visit the Global Iron and Steel Tracker on the Global Energy Monitor website.

References

  1. ↑ Gary Works, U.S. Steel, Retrieved on: Aug. 18, 2020
  2. ↑ "United States Steel Announces Major Modernization and Asset Revitalization at Gary Works - www.ussteel.com". www.ussteel.com. 2018-08-20. Retrieved 2021-11-02.{{cite web}}: CS1 maint: url-status (link)
  3. ↑ "US Steel to install pig iron capacity in Indiana | Argus Media". www.argusmedia.com. 2021-10-29. Retrieved 2021-11-02.
  4. ↑ Oktay, Ali (2021-08-18). "US Steel to shut another two blast furnaces for work in fourth quarter: spokeswoman". www.spglobal.com. Retrieved 2021-11-02.
  5. ↑ "Hazardous Waste Cleanup: U.S. Steel, Gary Works Facility - Gary, Indiana". EPA. 2005. Retrieved 2021-11-02.{{cite web}}: CS1 maint: url-status (link)
  6. ↑ Matheny, Keith (2016-11-23). "U.S. Steel fined $2.2M, required to make repairs for Midwest pollution". Detroit Free Press. Retrieved 2021-11-02.{{cite web}}: CS1 maint: url-status (link)
  7. ↑ "U. S. Steel Corporation Agrees to End Litigation, Improve Environmental Compliance at Its Three Midwest Facilities, Pay Civil Penalty of $2.2 Million and Perform Projects to Aid Communities Affected by U. S. Steel's Pollution". Department of Justice. 2016-11-22. Retrieved 2021-11-02.{{cite web}}: CS1 maint: url-status (link)
  8. ↑ https://web.archive.org/web/20210418104540/https://www.nwitimes.com/business/steel/u-s-steel-starts-layoffs-of-up-to-workers-at/article_a2368734-c52f-5ee2-8761-2b9f03734c30.html. Archived from the original on 2021-04-18. {{cite web}}: Missing or empty |title= (help)
  9. ↑ "U.S. Steel to lay off 244 workers when it idles tin operations at Gary Works". nwitimes.com. 2022-12-29. Archived from the original on 2025-04-28. Retrieved 2025-01-14.
  10. ↑ 10.0 10.1 10.2 10.3 https://web.archive.org/web/20240125024713/https://www.ussteel.com/about-us/locations. Archived from the original on 2024-01-25. {{cite web}}: Missing or empty |title= (help)
  11. ↑ https://web.archive.org/web/20220214142646/https://www.ussteel.com/sustainability/certifications. Archived from the original on 2022-02-14. {{cite web}}: Missing or empty |title= (help)
  12. ↑ 12.00 12.01 12.02 12.03 12.04 12.05 12.06 12.07 12.08 12.09 12.10 12.11 12.12 12.13 https://imis.aist.org/store/detail.aspx?id=PR-RU2023-1. {{cite web}}: Missing or empty |title= (help)
  13. ↑ 13.0 13.1 13.2 13.3 https://web.archive.org/web/20220710052907/https://www.spglobal.com/commodityinsights/en/market-insights/latest-news/metals/081821-us-steel-to-shut-another-two-blast-furnaces-for-work-in-fourth-quarter-spokeswoman. Archived from the original on 2022-07-10. {{cite web}}: Missing or empty |title= (help)
  14. ↑ 14.0 14.1 14.2 14.3 14.4 https://web.archive.org/web/20211027060812/https://www.argusmedia.com/en/news/2165052-us-steel-to-restart-gary-works-blast-furnace. Archived from the original on 2021-10-27. {{cite web}}: Missing or empty |title= (help)
  15. ↑ 15.0 15.1 15.2 https://web.archive.org/web/20220926184517/https://www.insideindianabusiness.com/articles/u-s-steel-idling-blast-furnace-at-gary-works. Archived from the original on 2022-09-26. {{cite web}}: Missing or empty |title= (help)
  16. ↑ https://web.archive.org/web/20191002155639/https://www.nwitimes.com/business/gary-works-sinter-plant-suffering-operational-difficulties/article_253b7e21-3a36-5d14-bf61-7150a436daaa.html. Archived from the original on 2019-10-02. {{cite web}}: Missing or empty |title= (help)
  17. ↑ (PDF) https://web.archive.org/web/20221130215256/https://www.epa.gov/sites/default/files/2015-12/documents/ironsteel.pdf. Archived from the original (PDF) on 2022-11-30. {{cite web}}: Missing or empty |title= (help)
  18. ↑ 18.0 18.1 18.2 18.3 18.4 18.5 (PDF) https://web.archive.org/web/20230311144635/https://s26.q4cdn.com/153509673/files/doc_financials/2022/ar/2022-Annual-Report.pdf. Archived from the original (PDF) on 2023-03-11. {{cite web}}: Missing or empty |title= (help)
  19. ↑ 19.0 19.1 19.2 (PDF) https://investors.ussteel.com/sec-filings/all-sec-filings/content/0001104659-24-035004/tm2332710d5_ars.pdf. {{cite web}}: Missing or empty |title= (help)
  20. ↑ 20.0 20.1 20.2 (PDF) https://www.sec.gov/Archives/edgar/data/1163302/000110465925026421/tm255512d2_ars.pdf. {{cite web}}: Missing or empty |title= (help)
  21. ↑ 21.0 21.1 https://imis.aist.org/store/detail.aspx?id=PR-RU2020-5. {{cite web}}: Missing or empty |title= (help)
  22. ↑ 22.0 22.1 https://imis.aist.org/store/detail.aspx?id=PR-RU2021-7. {{cite web}}: Missing or empty |title= (help)
  23. ↑ 23.0 23.1 https://imis.aist.org/store/detail.aspx?id=PR-RU2020-2. {{cite web}}: Missing or empty |title= (help)
  24. ↑ 24.0 24.1 24.2 24.3 24.4 https://imis.aist.org/store/detail.aspx?id=PR-RU2023-5. {{cite web}}: Missing or empty |title= (help)
  25. ↑ 25.0 25.1 25.2 https://imis.aist.org/store/detail.aspx?id=PR-RU2024-5. {{cite web}}: Missing or empty |title= (help)
  26. ↑ 26.0 26.1 (PDF) https://www.aist.org/getmedia/2eebb029-7978-49b6-867f-c6bcec31dc3e/204-205-april-2025.pdf. {{cite web}}: Missing or empty |title= (help)
  27. ↑ https://www.nwitimes.com/business/local/the-return-of-no-13/article_e89302c5-f9dd-558e-8116-56fc31752449.html. {{cite web}}: Missing or empty |title= (help)
  28. ↑ 28.0 28.1 (PDF) https://web.archive.org/web/20221128015619/https://www.ceramicsrefractories.saint-gobain.com/sites/hps-mac3-cma-pcr/files/assetbank_media/Iron---Steel-Blast-Furnace-brochure-2022-web-2274441.pdf. Archived from the original (PDF) on 2022-11-28. {{cite web}}: Missing or empty |title= (help)
  29. ↑ 29.0 29.1 29.2 29.3 "U. S. Steel and CarbonFree Sign Definitive Agreement to Capture Carbon Dioxide Emissions at One of the Largest North American Integrated Steel Mills". United States Steel Corporation. 2024-04-03. Archived from the original on 2025-04-28. Retrieved 2025-01-14.
  30. ↑ https://www.steelorbis.com/steel-news/latest-news/us-steel-to-reline-bf-no-14-at-gary-works-1425936.htm, https://www.ussteel.com/media/newsroom/-/blogs/u-s-steel-makes-strategic-progress-on-indiana-projects-backed-by-nippon-steel-partnership, https://www.nipponsteel.com/en/ir/library/settlement.html https://yieh.com/en/News/u-s-steel-starts-350-million-blast-furnace-reline-at-gary-works/161522, https://www.steelorbis.com/steel-news/latest-news/us-steel-to-reline-bf-no-14-at-gary-works-1425936.htm, https://www.ussteel.com/media/newsroom/-/blogs/u-s-steel-makes-strategic-progress-on-indiana-projects-backed-by-nippon-steel-partnership, https://www.nipponsteel.com/en/ir/library/settlement.html. {{cite web}}: Check |url= value (help); Missing or empty |title= (help)
  31. ↑ https://web.archive.org/web/20221209072603/http://www.nwitimes.com/business/local/u-s-steel-restarts-blast-furnace-4-at-gary-works-as-conditions-recover/article_61b32de8-143e-5cf7-9eef-0d9a7cada5dd.html. Archived from the original on 2022-12-09. {{cite web}}: Missing or empty |title= (help)
  32. ↑ 32.0 32.1 32.2 (PDF) https://web.archive.org/web/20170202182154/http://permits.air.idem.in.gov/37377d.pdf. Archived from the original (PDF) on 2017-02-02. {{cite web}}: Missing or empty |title= (help)
  33. ↑ https://songerservices.com/projects/rolling-pandemic-punches. {{cite web}}: Missing or empty |title= (help)
  34. ↑ (PDF) https://investors.ussteel.com/sec-filings/all-sec-filings/content/0001163302-18-000042/0001163302-18-000042.pdf. {{cite web}}: Missing or empty |title= (help)
  35. ↑ https://web.archive.org/web/20230327102405/https://www.aist.org/news/steel-news/2023/march/20-24-march-2023/u-s-steel-returns-idled-blast-furnace-to-service. Archived from the original on 2023-03-27. {{cite web}}: Missing or empty |title= (help)
  36. ↑ https://web.archive.org/web/20230202175103/https://www.matrixnac.com/project/uss-gary-works/. Archived from the original on 2023-02-02. {{cite web}}: Missing or empty |title= (help)
  37. ↑ 37.0 37.1 37.2 37.3 37.4 37.5 "2024 AIST Basic Oxygen Furnace Roundup". imis.aist.org. Archived from the original on 2025-03-10. Retrieved 2024-11-13.

Resources

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