You’ve probably seen the massive industrial skeleton rising out of the Alabama pines about 35 miles north of Mobile. If you’re a local, you just call it "the mill." But for the rest of the world, AM/NS Calvert Alabama has spent the last decade as a bit of a corporate mystery—a 50/50 joint venture with a name that sounds like an alphanumeric password.
Honestly, things just changed in a massive way.
As of June 2025, the "AM/NS" tag is technically a relic. ArcelorMittal officially bought out Nippon Steel’s 50% stake, taking full control of what is arguably the most advanced steel finishing facility in North America. They’ve rebranded it as ArcelorMittal Calvert, though everyone you talk to in Mount Vernon or Citronelle is still going to call it AM/NS for the next twenty years. Old habits die hard in the South.
The $1.5 Billion Divorce and Why It Matters
Why did Nippon Steel walk away from a literal gold mine? It wasn't because the plant was failing. Far from it. The facility generated over $600 million in EBITDA in 2024. The exit was basically a regulatory chess move. Nippon Steel needed to clear the path for its acquisition of U.S. Steel, and owning a massive chunk of Calvert was a major "anti-trust" red flag for the Department of Justice.
ArcelorMittal didn't blink. They paid roughly $1 in share consideration but took on nearly **$900 million in cash and loans**.
It’s a steal.
Before this, the plant was a "rerolling" facility. It didn't actually make steel; it imported massive slabs from places like Brazil and Mexico, then flattened and coated them. That changed recently with the fire-up of a new Electric Arc Furnace (EAF). Now, they are melting and pouring right there in Alabama. No more waiting on ships to cross the Atlantic just to get raw material.
What’s Actually Happening On-Site Right Now?
If you drove past the site today, you’d see a beehive of construction that has nothing to do with the existing mill. ArcelorMittal is currently dumping $1.2 billion into a brand-new facility for Non-Grain-Oriented Electrical Steel (NOES).
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If that sounds like jargon, think of it this way:
- No NOES, no Electric Vehicles (EVs).
- No NOES, no high-efficiency power grids.
- No NOES, no modern renewable energy.
The U.S. has been weirdly dependent on importing this stuff. By the time this new section of the plant is fully operational in 2027, they’ll be churning out 150,000 metric tons of electrical steel every year. It’s a massive play for the future of the American auto industry. They aren't just making "steel for cars" anymore; they are making the literal guts of the motors that drive them.
The Numbers That Actually Matter
Let's talk scale because pictures don't do it justice. The site covers 2,400 acres. That is roughly the size of 1,800 football fields.
- Capacity: The mill can process about 5.3 million metric tonnes of flat-rolled steel.
- Jobs: The new NOES project is bringing in 1,300 construction workers. Once it’s done, about 200 people will have permanent, high-paying roles there.
- Local Impact: The Port of Mobile recently deepened its channel to 50 feet. Why? Partly because of the sheer volume of material moving in and out of Calvert.
The "Green Steel" Myth vs. Reality
People love to throw around the term "low-carbon steel." In the industry, it's often more marketing than science. But at AM/NS Calvert, the move to an Electric Arc Furnace (EAF) is a legitimate shift. Traditional blast furnaces are carbon nightmares. EAFs, which use electricity to melt scrap and Hot Briquetted Iron (HBI), have a much lower footprint.
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The Calvert mill is now integrated with ArcelorMittal’s HBI plant in Texas. They ship the iron ore "bricks" to Alabama, melt them with recycled scrap, and produce "melted and poured in the USA" steel that meets the strict requirements of the Inflation Reduction Act.
It’s about money. Specifically, tax credits for car manufacturers.
If a Ford or a Chevy uses steel that was melted and poured here, they get a break. If it was imported? They don't. That’s why the expansion at Calvert isn't just a business growth story—it's a survival strategy for the domestic supply chain.
What Most People Miss About the Location
Calvert is a tiny spot on the map. It’s barely a census-designated place. So why build a multi-billion dollar empire there?
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It’s the river.
The facility has its own river terminal on the Tombigbee. Moving 5 million tons of steel by truck is impossible. Moving it by rail is expensive. But moving it by barge? That’s the secret sauce. You’ve got the rail lines running through the yard, the river at your back door, and the deep-water Port of Mobile just down the road. It is a logistical unicorn.
Looking Ahead: What to Expect in 2026 and Beyond
Right now, the site is in a transition phase. ArcelorMittal is assessing whether to add even more steelmaking capacity. They’ve already got the permits for air and water. The earthworks for the NOES plant are humming.
If you are looking for work or moving to the area, the next 24 months are going to be wild. The demand for skilled labor—welders, specialized electricians, and heavy equipment operators—is at an all-time high in Mobile County.
Actionable Insights for the Future:
- For Job Seekers: Focus on certifications related to EAF operations or electrical steel finishing. The "old school" steel worker is being replaced by technicians who can manage automated coating lines and complex metallurgy software.
- For Local Businesses: The influx of 1,300 construction workers through 2026 means housing and service demand in North Mobile will stay tight. Don't expect the "boom" to fade once construction ends; the permanent staff expansion is significant.
- For Investors/Partners: Keep a close eye on the slab supply agreement. ArcelorMittal still has a 7-year deal with Nippon to buy 750,000 tonnes of slabs annually. This ensures the plant doesn't run dry while they continue to build out their own internal melting capacity.
The transformation of AM/NS Calvert into a fully owned ArcelorMittal powerhouse is basically the closing of one chapter and the start of a much more aggressive one. They aren't just finishing steel anymore. They are building the foundation for the next fifty years of American manufacturing.
Monitor the 2027 startup date for the NOES facility. That is the moment Alabama becomes the heartbeat of the EV revolution.