Form 10-K 10-K 1 d10k.htm FORM 10-K
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UNITED STATES

SECURITIES AND EXCHANGE COMMISSION

WASHINGTON, D.C. 20549

FORM 10-K

[ x ] ANNUAL REPORT PURSUANT TO SECTION 13 OR 15(d) OF

THE SECURITIES EXCHANGE ACT OF 1934

For The Fiscal Year Ended December 31, 2006

OR

[    ] TRANSITION REPORT PURSUANT TO SECTION 13 OR 15(d)

OF THE SECURITIES EXCHANGE ACT OF 1934

Commission File Number 1-3610

ALCOA INC.

(Exact name of registrant as specified in its charter)

 

Pennsylvania   25-0317820
(State of incorporation)   (I.R.S. Employer Identification No.)

 

390 Park Avenue, New York, New York 10022-4608
(Address of principal executive offices)                 (Zip code)    

Registrant’s telephone numbers:

Investor Relations------------(212) 836-2674

Office of the Secretary-----------(212) 836-2732

Securities registered pursuant to Section 12(b) of the Act:

 

Title of each class

 

Name of each exchange on which registered

Common Stock, par value $1.00   New York Stock Exchange

Securities registered pursuant to Section 12(g) of the Act: None

Indicate by check mark if the registrant is a well-known seasoned issuer, as defined in Rule 405 of the Securities Act. Yes ü   No    .

Indicate by check mark if the registrant is not required to file reports pursuant to Section 13 or Section 15(d) of the Exchange Act. Yes       No ü.

Indicate by check mark whether the registrant (1) has filed all reports required to be filed by Section 13 or 15(d) of the Securities Exchange Act of 1934 during the preceding 12 months, and (2) has been subject to such filing requirements for the past 90 days. Yes ü   No     .

Indicate by check mark if disclosure of delinquent filers pursuant to Item 405 of Regulation S-K is not contained herein, and will not be contained, to the best of registrant’s knowledge, in definitive proxy or information statements incorporated by reference in Part III of this Form 10-K or any amendment to this Form 10-K.  [ü]

Indicate by check mark whether the registrant is a large accelerated filer, an accelerated filer, or a non-accelerated filer. See definition of “accelerated filer” and “large accelerated filer” in Rule 12b-2 of the Exchange Act.

Large accelerated filer [ü]                                 Accelerated filer [    ]                                 Non-accelerated filer [    ]

Indicate by check mark whether the registrant is a shell company (as defined in Rule 12b-2 of the Exchange Act). Yes       No ü.

The aggregate market value of the outstanding common stock, other than shares held by persons who may be deemed affiliates of the registrant, as of the last business day of the registrant’s most recently completed second fiscal quarter was approximately $28 billion. As of February 12, 2007, there were 869,536,783 shares of common stock, par value $1.00 per share, of the registrant outstanding.

Documents incorporated by reference.

Parts I, II and IV of this Form 10-K incorporate by reference certain information from the registrant’s 2006 Annual Report to Shareholders (Annual Report). Part III of this Form 10-K incorporates by reference certain information from the registrant’s definitive Proxy Statement for its 2007 Annual Meeting of Shareholders filed or to be filed pursuant to Regulation 14A (Proxy Statement).


Table of Contents

TABLE OF CONTENTS

 

          Page(s)
Part I      
Item 1.   

Business

   3
Item 1A.    Risk Factors    16
Item 1B.    Unresolved Staff Comments    18
Item 2.    Properties    19
Item 3.    Legal Proceedings    21
Item 4.    Submission of Matters to a Vote of Security Holders    27
Item 4A.    Executive Officers of the Registrant    27
Part II      
Item 5.    Market For Registrant’s Common Equity, Related Stockholder Matters and Issuer Purchases of Equity Securities    29
Item 6.    Selected Financial Data    29
Item 7.    Management’s Discussion and Analysis of Financial Condition and Results of Operations    30
Item 7A.    Quantitative and Qualitative Disclosures About Market Risk    30
Item 8.    Financial Statements and Supplementary Data    30
Item 9.    Changes in and Disagreements With Accountants on Accounting and Financial Disclosure    30
Item 9A.    Controls and Procedures    30
Item 9B.    Other Information    30
Part III      
Item 10.    Directors, Executive Officers and Corporate Governance    31
Item 11.    Executive Compensation    31
Item 12.    Security Ownership of Certain Beneficial Owners and Management and Related Stockholder Matters    32
Item 13.    Certain Relationships and Related Transactions, and Director Independence    33
Item 14.    Principal Accountant Fees and Services    33
Part IV      
Item 15.    Exhibits and Financial Statement Schedules    33
Signatures       42

Note on Incorporation by Reference

In this Form 10-K, selected items of information and data are incorporated by reference to portions of the Annual Report and Proxy Statement. Unless otherwise provided herein, any reference in this report to disclosures in the Annual Report or Proxy Statement shall constitute incorporation by reference of that specific disclosure into this Form 10-K.


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ALCOA INC.

Formed in 1888, Alcoa Inc. is a Pennsylvania corporation with its principal office in New York, New York. In this report, unless the context otherwise requires, “Alcoa” or the “company” means Alcoa Inc. and all subsidiaries consolidated for the purposes of its financial statements.

The company’s Internet address is http://www.alcoa.com. Alcoa makes available free of charge on or through its website its annual report on Form 10-K, quarterly reports on Form 10-Q, current reports on Form 8-K, and amendments to those reports filed or furnished pursuant to Section 13(a) or 15(d) of the Securities Exchange Act of 1934 as soon as reasonably practicable after the company electronically files such material with, or furnishes it to, the Securities and Exchange Commission (SEC). The SEC maintains an Internet site that contains these reports at http://www.sec.gov.

PART I

Item 1.     Business.

Description of the Business

Information describing Alcoa’s businesses can be found in the Annual Report at the indicated pages:

 

Item

   Page(s)  

Discussion of Recent Business Developments:

  

Management’s Discussion and Analysis of Financial Condition and Results of Operations:

Overview—Results of Operations (Earnings Summary)

   25  

Notes to Consolidated Financial Statements

  

Note B. Discontinued Operations and Assets Held for Sale

   51  

Note D. Restructuring and Other Charges

   52  

Note F. Acquisitions and Divestitures

   54  

Segment Information:

  

Business Descriptions, Principal Products, Principal Markets, Methods of Distribution, Seasonality and Dependence Upon Customers:

  

Alumina

   30 *

Primary Metals

   31 *

Flat-Rolled Products

   31 *

Extruded and End Products

   32 *

Engineered Solutions

   32 *

Packaging and Consumer

   32 *

Financial Information about Segments and Financial Information about Geographic Areas:

  

Note Q. Segment and Geographic Area Information

   58  

 

* Excluding captions, charts, diagrams and related notes.

Overview

Alcoa is the world’s leading producer of primary aluminum, fabricated aluminum, and alumina, and is active in all major aspects of the industry: technology, mining, refining, smelting, fabricating, and recycling. Aluminum is a commodity that is traded on the London Metal Exchange (LME) and priced daily based on market supply and demand. Aluminum and alumina represent approximately three-fourths of Alcoa’s revenues, and the price of aluminum influences the operating results of Alcoa. Nonaluminum products include precision castings, industrial fasteners, consumer products, food service and flexible packaging products, plastic closures, and electrical distribution systems

 

3


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for cars and trucks. Alcoa’s products are used worldwide in aircraft, automobiles, commercial transportation, packaging, consumer products, building and construction, and industrial applications.

Alcoa is a global company operating in 44 countries. North America is the largest market with 59% of Alcoa’s revenues. Europe is also a significant market with 24% of the company’s revenues. In addition, Alcoa has investments and activities in Australia, Brazil, China, Iceland, Jamaica and Russia which present opportunities for substantial growth. Governmental policies and other economic factors, including inflation and fluctuations in foreign currency exchange rates and interest rates, affect the results of operations in these countries.

Alcoa’s operations consist of six worldwide segments: Alumina, Primary Metals, Flat-Rolled Products, Extruded and End Products, Engineered Solutions, and Packaging and Consumer.

The Alumina segment primarily consists of a series of affiliated operating entities referred to as Alcoa World Alumina and Chemicals (AWAC). Generally, Alcoa owns 60% and Alumina Limited owns 40% of these individual entities. For more information on AWAC, see Exhibit Nos.10 (a) through 10(f) to this report.

Bauxite Interests

Aluminum is one of the most plentiful elements in the earth’s crust. Aluminum is produced primarily from bauxite, an ore containing aluminum in the form of aluminum oxide, commonly referred to as alumina. Aluminum is made by extracting alumina from bauxite and then removing oxygen from the alumina. Alcoa processes most of the bauxite that it mines into alumina. The company obtains bauxite from reserves held by AWAC, from the company’s interests in the countries listed in the chart below, and under both long-term and short-term contracts and mining leases. In 2006, Alcoa consumed 33.9 million metric tons (mt) of bauxite from its own reserves, 6.6 million mt from related third parties and 3.1 million mt from unrelated third parties. Alcoa’s present sources of bauxite are sufficient to meet the forecasted requirements of its alumina refining operations for the foreseeable future. The following table provides information regarding the company’s bauxite interests:

Alcoa Active Bauxite Interests1

 

Country   Project    Mining Rights (% Entitlement )   

Expiration

Date of

Mining

Rights

 

Australia

  Darling Range Mines    Alcoa of Australia Limited (AofA)2 (100%)    2045  

Brazil

  Poços de Caldas    Alcoa Aluminio S.A. (Aluminio) 3 (100%)    2020 4
     Trombetas    Mineração Rio do Norte S.A. (MRN)5 (100%)    2046 4

Guinea

  Boké    Compagnie des Bauxites de Guinée (CBG)6 (100%)    2038 7

Jamaica

  Clarendon/Manchester Plateau   

Alcoa Minerals of Jamaica, L.L.C.8 (50%)

Clarendon Alumina Production Ltd.9 (50%)

   2042  

Suriname

  Lelydorp   

BHP Billiton (45%)

Suriname Aluminum Company, L.L.C. (Suralco)8 (55%)

   2033 10
     Coermotibo   

BHP Billiton (45%)

Suralco (55%)

   2033 10
     Kaimangrasi   

BHP Billiton (45%)

Suralco (55%)

   2033  10

 

1

Alcoa also has interests at the following locations that are bauxite reserves or do not currently produce bauxite: Cape Bougainville and Mitchell Plateau in Australia, Juruti in Brazil (scheduled for completion in 2008 and expected to initially produce 2.6 million mt per year (mtpy)) and Klaverblad (expected to produce bauxite beginning in 2007), Brownsberg, Coermotibo DS, Lely Mountains, and Nassau all in eastern Suriname.

 

2

AofA is part of the AWAC group of companies and is owned 60% by Alcoa and 40% by Alumina Limited.

 

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3

In August 2003, Alcoa acquired the 40.9% shareholding in Aluminio held by affiliates of Camargo Correa S.A. (collectively the “Camargo Group”). Prior to the acquisition, Alcoa had owned approximately 59% of Aluminio and the Camargo Group had been the principal minority shareholder since 1984.

 

4

Brazilian mineral legislation does not establish the duration of mining concessions. The concession remains in force until the complete exhaustion of the deposit. The company estimates that (i) the concessions at Poços de Caldas will last at least until 2020 and (ii) the concessions at Trombetas will last until 2046. Depending, however, on actual and future needs, the rate at which the deposits are explored and government approval, the concessions may be extended to (or expire at) a later (or an earlier) date.

 

5

Aluminio holds an 8.6% interest, Abalco S.A. (Abalco) holds a 4.6% interest and Alcoa World Alumina LLC (AWA LLC) holds a 5% interest in MRN. Abalco and AWA LLC are both part of the AWAC group of companies and are owned 60% by Alcoa and 40% by Alumina Limited. MRN is jointly owned with affiliates of Alcan Inc. (Alcan), Companhia Brasileira de Aluminio, Companhia Vale do Rio Doce, BHP Billiton Plc (BHP Billiton) and Norsk Hydro. Aluminio, Abalco, and AWA LLC purchase bauxite from MRN under long-term supply contracts.

 

6

AWA LLC owns a 45% interest in Halco (Mining), Inc. Halco owns 51% and the Guinean Government owns 49% of CBG, which has the exclusive right through 2038 to develop and mine bauxite in certain areas within a 10,000 square-mile perimeter in northwestern Guinea.

 

7

AWA LLC has a bauxite purchase contract with CBG that will provide Alcoa with bauxite through 2011.

 

8

This entity is part of the AWAC group of companies and is owned 60% by Alcoa and 40% by Alumina Limited.

 

9

Clarendon Alumina Production Ltd. is a wholly-owned subsidiary of the Government of Jamaica.

 

10

While mining rights extend until 2033, bauxite reserves may be exhausted before that date. Alternative bauxite resources are being evaluated in the western part of Suriname.

Alumina Refining Facilities and Capacity

Alcoa is the world’s leading producer of alumina. Alcoa’s alumina refining facilities and its worldwide alumina capacity are shown in the following table:

Alcoa Worldwide Alumina Refining Capacity

 

Country    Facility   

Owners

(% of Ownership)

   Nameplate
Capacity1
(000 MTPY)
   

Alcoa

Consolidated
Capacity2

(000 MTPY)

Australia

   Kwinana    AofA3 (100%)    2,150     2,150
     Pinjarra    AofA (100%)    4,234 4   4,234
     Wagerup    AofA (100%)    2,480     2,480

Brazil

   Poços de Caldas    Aluminio (100%)    390     390
     São Luís (Alumar)   

Abalco3 (18.9%)

Alcan5 (10%)

Aluminio (35.1%)

BHP Billiton5 (36%)

   1,400     756

Jamaica

   Jamalco   

Alcoa Minerals of Jamaica, L.L.C.3 (50%)

Clarendon Alumina Production Ltd. (50%)

   1,275     638

Spain

   San Ciprián    Alúmina Española, S.A.3 (100%)    1,450     1,450

Suriname

   Suralco   

BHP Billiton5 (45%)

Suralco3 (55%)

   2,207     1,214

U.S.

   Point Comfort, Tex.    AWA LLC3 (100%)    2,305     2,305

TOTAL

             17,891     15,617

 

1

Nameplate capacity is an estimate based on design capacity and normal operating efficiencies and does not necessarily represent maximum possible production.

 

2

The figures in this column reflect Alcoa’s share of production from these facilities. For facilities owned by AWAC entities, Alcoa takes 100% of the production.

 

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3

This entity is part of the AWAC group of companies and is owned 60% by Alcoa and 40% by Alumina Limited.

 

4

In 2004, Alcoa received the Western Australian Government’s environmental approval for its previously announced Pinjarra alumina refinery efficiency upgrade, which would increase production at the facility by 657,000 mtpy. Ramp up to full production at the Pinjarra refinery was achieved in the fourth quarter of 2006. Nameplate capacity was reduced, however, during the month of December due to a power failure experienced at the refinery. Full power has since been restored.

 

5

The named company or an affiliate holds this interest.

In January 2005, Alcoa and the Government of the Republic of Ghana announced the signing of a Memorandum of Understanding (MOU), under which the parties would evaluate the possible development of an integrated aluminum industry in Ghana, including bauxite mining, alumina refining, aluminum production, and rail transportation infrastructure upgrades. Alcoa has worked with the Government to conduct feasibility studies related to the bauxite resources. The parties expect to continue discussions during 2007 on the feasibility of the project.

In September 2005, Alcoa announced that its Board of Directors approved plans to make further investments in the company’s Brazilian “upstream” operations, including a 2.1 million mtpy expansion of the Alumar consortium alumina refinery in São Luís, state of Maranhao (expected to increase the refinery’s capacity from 1.4 million mtpy to approximately 3.5 million mtpy beginning in late 2008, with Alcoa’s share of the total facility output more than doubling to 1.89 million mtpy based on its 54% ownership stake through AWAC) and the modernization of the Poços de Caldas aluminum smelter, in the state of Minas Gerais.

In November 2005, AWA LLC and Alcan announced the signing of a Basic Agreement with the Government of Guinea that sets forth the framework for development of a 1.5 million mtpy alumina refinery in Guinea. The Basic Agreement was approved by the Guinean National Assembly in May of 2006 and was promulgated into law by decree of the President of Guinea in July of 2006.

In April 2006, AWAC signed an MOU with Vietnam National Coal-Minerals Industries Group (Vinacomin) under which the parties will explore the feasibility of creating a joint venture to develop a bauxite mine and alumina refinery in the Dak Nong province of Vietnam. If established, the joint venture would be 51% owned by Vinacomin and 49% owned by AWAC.

In September 2006, Alcoa received environmental approval from the Government of Western Australia for expansion of the Wagerup alumina refinery to a maximum capacity of 4.7 million mtpy, a potential increase of over 2 million mtpy. This approval includes a variety of environmental conditions that must be satisfied before Alcoa can seek construction approval for the project. The environmental approval paves the way for Alcoa to proceed to the next stage of project design (feasibility study) following completion of pre-feasibility work scheduled for the first half of 2007.

The 1.5 million mtpy planned expansion of the Jamalco alumina refinery in Clarendon, Jamaica is subject to supply of natural gas by the Government of Jamaica and acceptable market conditions. The Government of Jamaica continues to negotiate with third party suppliers to procure natural gas to be supplied to Jamalco, but no final agreement has been reached. Alcoa is proceeding with the Early Works Program, which will add 146,000 mtpy of production to Jamalco, bringing the total capacity to 1.420 million mtpy. The Early Works Program is expected to be substantially complete by the end of the first quarter of 2007. As a result of the Early Works Program, Alcoa’s ownership in Jamalco will increase to approximately 55%, with the Government of Jamaica owning approximately 45%.

 

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Primary Aluminum Facilities and Capacity

The company’s primary aluminum smelters and their respective capacities are shown in the following table:

Alcoa Worldwide Smelting Capacity

 

Country   Facility  

Owners

(% Of Ownership)

 

Nameplate
Capacity1

(000 MTPY)

   

Alcoa

Consolidated

Capacity2

(000 MTPY)

 

Australia

  Point Henry   AofA (100%)   185     185 3
    Portland  

AofA (55%)

CITIC (22.5%)

Marubeni (22.5%)

  353     194 3

Brazil

  Poços de Caldas   Aluminio (100%)   96     96  
    São Luís (Alumar)  

Aluminio (60%)

BHP Billiton (40%)

  438     263  

Canada

  Baie Comeau, Que.   Alcoa (100%)   438     438  
    Bécancour, Que.  

Alcoa (74.95%)

Alcan4 (25.05%)

  409     307  
    Deschambault, Que.   Alcoa (100%)   254     254  

Italy

  Fusina   Alcoa (100%)   44     44  
    Portovesme   Alcoa (100%)   150     150  

Spain

  Avilés   Alcoa (100%)   90     90  
    La Coruña   Alcoa (100%)   84     84  
    San Ciprián   Alcoa (100%)   225     225  

U.S.

  Evansville, Ind. (Warrick)   Alcoa (100%)   309 5   309 5
    Frederick, Md. (Eastalco)   Alcoa (100%)   195 6   195 6
    Badin, N.C.   Alcoa (100%)   60 7   60 7
    Massena West, N.Y.   Alcoa (100%)   130     130  
    Massena East, N.Y.   Alcoa (100%)   125     125  
    Mount Holly, S.C.  

Alcoa (50.33%)

Century Aluminum Company (49.67%)

  229     115  
    Alcoa, Tenn.   Alcoa (100%)   215     215