Opportunities exist in steel manufacturing in a variety of occupations, but the largest group of workers-47 percent- is employed in production occupations. Other large groups of workers are installation, maintenance, repair, workers and transportation and material-moving workers.
Although the steel making procedure varies with the type of furnace used, the jobs associated with the various processes are similar. Most jobs in steel mills can be classified into 1 of 3 types: Operators, maintenance and repair workers, and supervisors and managers. In addition, significant numbers of electricians, engineers, inspectors and testers, and material-moving workers are needed to assist in the production process and repair of equipment. Workers generally are assigned to work in a particular sector of the production line, such as the blast furnace or rolling mill areas, and their titles reflect the types of machines they work on.
At integrated mills, production begins when material-moving workers load iron ore, coke, and limestone into the top of a blast furnace. As the materials are heated, a chemical reaction frees the iron from other elements in the ore. Metal-refining furnace operators and tenders, also known as blowers and melters, direct the overall operation of the furnace to melt and refine metal before casting or to produce specific types of steel. They gather information on the characteristics of the raw materials they will use and the type and quality of steel they are expected to produce. They direct the loading of the furnace with raw materials and supervise the taking of samples, to ensure that the steel has the desired qualities. They may also coordinate the loading and melting of raw materials with the steel molding or casting operation to avoid delays in production.
Generally, either a basic oxygen or an electric arc furnace is used to make steel. Operators and tenders use controls to tilt the furnace to receive the raw materials. Once they have righted the furnace, they use levers and buttons to control the flow of oxygen and other materials into the furnace. During the production process, testers routinely take samples to be analyzed. Based on this analysis, operators determine how much longer they must process the steel or what materials they must add to meet specifications. Operators also pay close attention to conditions within the furnace and correct any problems that arise during the production process.
Metal pourers and casters tend machines that release the molten steel from the ladle at a controlled rate into water-cooled molds, where it solidifies into semifinished shapes. This process is called “continuous casting.” These shapes are then cut to desired lengths as they emerge from the caster. During this process, operators monitor the flow of raw steel and the supply of water to the mold.
The “rolling” method is used to shape most steel processed in steel mills. In this method, hot steel is squeezed between two cylinders, or “rollers,” which flatten or shape the steel. Rolling machine operators operate the rolling mills that produce the finished product; the quality of the product and the speed at which the work is completed depend on the operator’s skills. Placing the steel and positioning the rollers are very important, for they control the product’s final shape. Improperly adjusted equipment may damage the rolling mill or gears.
Extruding and drawing machine operators control equipment that extrudes, or draws, metal materials into tubes, rods, hoses, wire, bars, or structural shapes. Cutting, punching, and press machine operators operate machines that saw, cut, shear, slit, punch, crimp, notch, bend, or straighten metal. Welding, soldering, and brazing workers join metal components or fill holes, indentations, or seams of fabricated metal products. Multiple machine tool operators are skilled in the operation of more than one type of cutting or forming machine tool or robot.
Team assemblers and leaders work as part of a team responsible for assembling an entire product or component of a product. Team assemblers can perform all tasks conducted by the team in the assembly process and rotate through all or most of them rather than being assigned to a specific task on a permanent basis. They may participate in making management decisions affecting the work. Machinists operate a variety of machine tools to produce precision parts and instruments. They may fabricate and modify parts to make or repair machine tools or maintain industrial machines. Inspectors, testers, sorters, samplers, and weighers check parts or products for defects, wear, and deviations from specifications.
Millwrights are employed to install and maintain much of the sophisticated machinery in steel mills. As the technology becomes more advanced, they work more closely with electricians, who help repair and install electrical equipment such as computer controls for machine tools.
Engineers, chemists, and computer specialists are playing an increasing role at steel mills, helping to address a variety of issues. Industrial engineers make plants more productive and energy efficient by designing and installing the latest technology. Mechanical engineers often are found in supervisory or management jobs, helping to solve mechanical problems on the production line. Environmental engineers design environmental control systems to maintain water and air quality standards or to clean up old sites. Metallurgical engineers work with the metals and ores that go into steel in order to change or improve its properties or to find new applications for steel.
Additionally, as with most companies, there are accountants, sales agents, various managers, and administrative and clerical workers who run the company and process paperwork.
