Hybar CEO Dave Stickler announced the successful start of production with the words “Mission accomplished” and thanked the company's employees and contractors. Stickler noted in a statement that the first of 100 billets purchased from Steel Dynamics Inc (SDI) was converted into ribbed rebar on the evening of May 28.
Commissioning of the 105-ton capacity direct current (DC) electric arc furnace and continuous caster is scheduled to begin next month. Stickler emphasized that although the DC type EAF supplied by SMS Group has a high initial investment cost, it offers up to a 10% advantage in terms of energy efficiency. “There will be 40 tons of hot castings in this plant. We will run this plant like a Ferrari,” he added.
Stating that the Hybar plant will consume approximately 770,000 short tons of scrap iron annually, Stickler said that they do not expect any problems with raw material supply in the “scrap-rich” market conditions in the US.
The first arc of the furnace is scheduled to be lit on July 4, Independence Day. The commissioning of the rolling mill, finishing plant and water treatment plant is also expected to be completed within the next 30 days.
The plant is expected to be fully commissioned in late June or early July, with commercial production to start by late summer. The company aims to produce at least 200,000 short tons of ribbed rebar in the second half of 2025. The plant has an annual capacity of 630,000 short tons, which is expected to increase to 700,000 tons with current efficiency.
Stickler noted that around 50% of the plant's annual production has already been purchased by three major customers.
Targeting steel production with renewable energy
Hybar operates under the umbrella of Green & Clean Holdings in line with its sustainability goals. The company's port operations are carried out by Green & Clean Terminals and its energy infrastructure by Green & Clean Power. The port on the banks of the Mississippi River has been in operation since January, loading and unloading both scrap and agricultural products.
The factory's energy needs were planned to be met by on-site solar panels and battery storage systems. The company aims to produce steel with 100% renewable energy when all systems are fully operational. “When everything is perfectly synchronized and the sun is shining, we will produce ribbed rebar with 100% renewable energy,” Stickler stated, adding that this goal is important from an environmental perspective.
Stickler noted that they will not charge customers extra for “the world's greenest ribbed rebar”, but that sustainable production may be preferable for some customers. “If prices, payment terms and the commercial team are on the same level, some customers may prefer materials from sustainable plants over products made in plants built 80-100 years ago,” he added.
New facilities on the way
Hybar's growth ambitions are not limited to the Arkansas plant. Stickler stated that they are planning to build three new ribbed rebar plants and a potential flat products plant, that the search for locations for two new plants is ongoing and that they may announce a new investment later this year.
Market uncertainty affects investments
Stickler stated that the construction market usually picks up in the summer months but gives mixed signals in the current conditions. Stating that there is hesitation in private sector investments due to global tariffs and expected tax regulations, Stickler stated, “When you don't know what the rules are, you need to be cautious. But once there is clarity, investments and projects will gain momentum,”.
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