The steel industry is the foundation of the global economy. The US produced 81.4 million tonnes of crude steel in 2023, and industry revenue is projected to reach nearly $140 billion by 2025. In such a competitive industry, ongoing innovation is essential for manufacturers to maintain leadership and adapt to evolving market demands.

Steel manufacturers have always found ways to innovate, improve performance, and enhance safety. They have adopted Electric Arc Furnaces (EAFs) to enhance efficiency, sustainability, and profitability, and have integrated connected devices and sensors to gain greater visibility and insight into their operations.

Despite these advances, many critical processes still rely on scheduled physical inspections. Traditional inspection methods depend heavily on manual labor, which can lead to inefficiencies, increased safety risks, and inconsistent results. Not only are these inspections time-consuming, expensive, and limited in their effectiveness, but they also put workers at risk. Today, steel manufacturers require a new approach to monitoring that reduces the need for physical inspections and enhances workplace safety throughout the entire production process. Advanced inspection technologies play a critical role in ensuring both safety and operational efficiency in modern steel manufacturing.

To see how you can gain greater visibility into the health and performance of critical assets, click to download our latest white paper: Mitigating Risk in the Steel Industry – The Benefits of Continuous Thermal Monitoring Adopting new inspection technologies offers key advantages such as improved quality control, greater efficiency, enhanced safety, and cost savings, all of which are vital for staying ahead in the competitive steel industry.

Steel plants are inherently dangerous environments. Fortunately, the industry has made tremendous progress in protecting workers over the past decade. From 2014 to 2023, the number of lost-time injuries globally decreased by more than half, from 5,040 to 2,486 per year. During the same period, fatalities fell from 130 to 61 per year.

Slips and falls, moving machinery, manual task tools, and gassing and asphyxiation were among the most common causes of workplace incidents.

Physical inspections require workers to operate in hazardous areas. Ladle monitoring and EAF monitoring, for example, require highly skilled technicians to access and evaluate the condition of the asset. Workers use a range of handheld sensors, visual cues, and experience to check for structural damage, wear patterns, slag buildup, or other mechanical issues.

During an inspection, technicians are exposed to extreme temperatures, molten steel and slag, toxic fumes, and heavy equipment. In EAF operations, personnel may also work next to live electrical components or active furnace operations, where arc flashes, molten metal splashes, and radiant heat pose significant risks. Manual inspections can expose workers to additional safety hazards that could be mitigated with automated inspection technologies.

In addition to the safety risks, inspections disrupt operations and increase the total production cost. A single inspection, for example, can take between 30 and 60 minutes and require equipment shutdowns. Manual inspections can also lead to material waste and a risk of compromising quality due to missed or inaccurate defect detection. The subjective nature of inspections means they can be prone to human error, and visibility is limited in low-light or obstructed areas. Relying solely on human inspectors can limit the accuracy and consistency of defect detection, thereby increasing the potential for undetected issues.

Finally, scheduled inspections only provide a periodic snapshot of the asset. Faults that occur between inspections can go undetected and unrepaired until a major failure occurs. This lack of timely and proactive maintenance increases the likelihood of dangerous breakouts or steam explosions.

Manual inspections were necessary in the past, and they still serve as a useful redundancy today. But steel manufacturers need to move away from traditional inspections by implementing technologies that improve safety for workers.

Continuous Thermal Monitoring solutions leverage advanced thermal imaging cameras to provide steel manufacturers with 24/7 coverage of critical equipment throughout the production process. The inspection process is automated and more comprehensive than manual methods, enabling continuous evaluation and enhanced detection capabilities.

Compared to traditional inspections, Continuous Thermal Monitoring allows Operators to monitor the health and performance of high-value assets from a safe, centralized location.

Thermal cameras capture real-time video and temperature data, providing operators with immediate data that enables them to detect anomalies quickly and take corrective action to prevent equipment degradation, water leaks, or other faults before catastrophic failure occurs. Sophisticated visualization software allows Operators to view and control multiple cameras simultaneously. Detailed data and inspection results are automatically recorded, providing support for quality control, traceability, and regulatory compliance.

The steel industry will continue to find ways to innovate and improve performance. Continuous Thermal Monitoring solutions build on these advancements to provide greater visibility and insight into critical production processes. Real-time thermal data can be utilized in critical applications, such as ladle refractory lining and Electric Arc Furnace monitoring, to optimize performance and reduce maintenance costs. Ongoing analysis of this data supports continuous improvement by refining inspection criteria, enhancing quality control, and driving operational efficiency over time.

Rather than rely on time-based physical inspections or reactive maintenance strategies, steel plants can take a proactive approach that improves asset utilization, enhances workplace safety, and mitigates the risk of catastrophic equipment failure. These technologies help optimize production processes and improve overall efficiency by streamlining operations and identifying areas for improvement. Additionally, they deliver significant cost savings through reduced maintenance, minimized rework, and improved asset utilization.

To learn more about the benefits of Continuous Thermal Monitoring and how you can deploy these solutions in your facility, enter your information below to download our latest white paper, “Mitigating Risk in the Steel Industry – The Benefits of Continuous Thermal Monitoring.”