Designed to Learn: How Big River 2 Redefines Continuous Improvement - www.ussteel.com
Designed to Learn: How Big River 2 Redefines Continuous Improvement
Jan 12 , 2026
At U. S. Steel’s Big River Steel Works, “learn something new every day” is more than a saying—it’s the operating principle of a high-tech steel mill designed to push what’s possible in modern steelmaking.
That is especially true at our Big River 2 (BR2) expansion, where our state-of-the-art “learning mill” puts 60 terabytes of data to work every year. We’re putting automation and machine learning in the hands of highly qualified engineers who are focused on delivering high-quality, highly engineered steel solutions tailored to meet our customers’ unique needs in a safe, environmentally responsible manner.
For our customers, this learning mindset translates directly into more consistent quality, tighter tolerances, and greater confidence that steel will perform exactly as expected, order after order.
ESP: Where modern technology meets modern steelmaking
The centerpiece of BR2 is our Endless Strip Process (ESP)—the first of its kind in North America. The ESP produces massive amounts of data that fuels continuous improvement, not only for IT, but for our metallurgists, quality engineers, technical services reps and operations teams. Process data is constantly fed back into the ESP, which then “remembers” to make the right adjustments automatically. Each coil teaches the line something new, and the more we run, the better the system gets.
Operationally, the ESP is also unique because it’s capable of producing hot-rolled coils at gauges traditionally associated with cold-rolled product, all while maintaining exceptional uniformity within a single coil and from coil to coil. That’s because the ESP keeps on learning. The quality results have been fantastic and that’s not just us saying so. That’s straight from our customers, and they know best.
Hot autonomous coil storage: Unparalleled safety and efficiency
When planning got underway for BR2, we took lessons from the construction and operation of Big River 1 (BR1) to identify enhancements. One of those opportunities involved the implementation of more automation and artificial intelligence in our coil storage facilities to improve safety, efficiency, and product quality. The most advanced of those is our hot autonomous coil storage (HACS). Capable of running 24/7 without human intervention, BR2’s HACS receives every coil produced at the ESP and is fully integrated into the day-to-day operations of the entire mill.
In line with our S.T.E.E.L. Principles, let’s talk “Safety First.” Coil movements in steel mills require precision to reduce the risk to employees. They can also pose risks due to high temperatures and sharp edges. The use of automation and AI to reduce employee operators makes the HACS area a safer environment and improves the overall safety of Big River Steel Works.
There are significant benefits for our customers, too. Automated coil movement reduces damage and safeguards quality.
Finally, there are efficiency gains that boost our bottom line. The systems at HACS use order data to position, store and move coils based on customer finishing and delivery requirements as well as scheduling in our finishing facilities. This improves efficiency and supports just-in-time delivery.
Other key features include:
- Increased crane capacity for greater movement flexibility.
- Expanded storage to support future growth.
- Improved information architecture for reporting, troubleshooting, and quality assurance.
The future of BR2: Connecting all the pieces
Like many businesses in our sector, we follow the Purdue model for industrial control systems. The advanced systems at BR2 allow us to more effectively secure, process and centralize data across all levels of the IT infrastructure.
As the mill continues to scale, this centralized approach will empower us to integrate all aspects of the business. The result? We’ll spend less time solving problems and more time anticipating solutions. That ability to anticipate—not just react—becomes even more powerful at the scale and complexity of the expanded Big River Steel Works.
Building a more intelligent operation
In a learning mill like BR2, intelligence isn’t confined to one process or platform; it’s shared across the operation to support safer work, higher quality, and more reliable outcomes for our customers. Through machine learning, decisions happen faster, adjustments are more precise, and opportunities for improvement are identified sooner, often before issues are visible to the human eye.
Incorporating generative AI will only enhance this process. We’re currently building a platform for using agentic AI to analyze data from our ESP and connect those hidden insights to our broader business systems. Imagine a system that can analyze live production data alongside order entry, supply chain management and scheduling, then provide real-time feedback to operations.
Forging our future
At U. S. Steel’s Big River Steel Works—and especially within BR2—continuous improvement starts with learning: learning from every coil, every data point, and every decision made on the mill floor. That’s what it truly means to “learn something new every day” in a high‑tech steelmaking environment. By designing a mill that gets smarter over time, we’re not just improving how we operate, we’re creating lasting value for our customers, empowering our people, and helping forge the future of American steelmaking.
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