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Gerdau (Cosigua): Business Model Canvas - Long Steel, Recycling & Diversified Growth
Explore the strategic framework behind Gerdau (Cosigua)'s business model - this Business Model Canvas highlights how the company delivers value through long steel, carbon and specialty products, recycling, and bio-energy while clarifying its customer segments, monetization logic, and core operational drivers.
Partnerships
Strategic Scrap Metal Suppliers
Gerdau (Cosigua) sources ~60% of feedstock from a network of independent scrap collectors and industrial recyclers that supply its Electric Arc Furnaces; by end-2025 these partners are linked via digital platforms tracking material quality and CO2 intensity, cutting sorting losses ~12% and enabling reported Scope 3 traceability for ~48% of scrap volume, securing steady inputs and supporting local circular economies.
Energy and Utility Providers
Gerdau (Cosigua) secures stable, low-cost power via long-term power purchase agreements and JV renewables-including a 2024-backed 120 MW wind PPA in Brazil-cutting energy-price exposure and supporting a 30% CO2 intensity reduction target by 2030. Natural gas contracts cover reheating furnaces and thermal needs; fuel costs still represent ~18% of operating input spend, so these partnerships directly lower margin volatility.
Joint Venture Technology Partners
Collaborations with international tech firms and specialty steel makers let Gerdau (Cosigua) produce high-value steels for auto and aerospace, sharing IP and expertise to cut R&D risk and speed time-to-market; joint projects raised specialty-steel sales share to about 18% of Cosigua revenue by 2024. By 2025, alliances concentrated on Industry 4.0-digital manufacturing, predictive maintenance, and AI process control-reducing production downtime by ~12% in pilot lines.
Logistics and Infrastructure Operators
Gerdau (Cosigua) relies on long-term contracts with rail, coastal shipping, and trucking firms plus port operators near its Rio de Janeiro Cosigua plant to move ~3.2 Mtpa of steel and 1.1 Mtpa of inbound ore, cutting transit costs ~6% and CO2/km by an estimated 12% through modal shifts (2024 internal logistics review).
- ~3.2 Mtpa finished steel throughput
- 1.1 Mtpa inbound ore via rail/ship
- ~6% lower transport costs (2024)
- ~12% reduced transport carbon intensity
- Real-time tracking for delivery reliability
Academic and Research Institutions
Gerdau (Cosigua) partners with universities and metallurgical centers to co-develop new steel alloys and boost recycling efficiency; by end-2025 these collaborations pivot to hydrogen-based steelmaking and advanced carbon capture R&D, with ~30% of joint projects funded for low-carbon tech.
These ties supply a steady pipeline of skilled engineers and researchers, contributing to a 12% improvement in pilot-scale energy efficiency and supporting Cosigua's long-term competitiveness.
- ~30% of collaborative projects focused on low-carbon tech by 2025
- 12% pilot energy-efficiency gains from academic-led programs
- Ongoing alloy and recycling process joint patents (2022-2025)
Gerdau boosts traceable scrap, cuts losses and emissions; specialty steel lifts revenue
Gerdau (Cosigua) secures ~60% scrap feedstock from independent collectors, enabling Scope 3 traceability for ~48% of scrap by end-2025 and cutting sorting losses ~12%; long-term PPAs and a 2024 120 MW wind PPA lower energy-price exposure and support a 30% CO2 intensity cut by 2030; partnerships raised specialty-steel share to ~18% of revenue and reduced pilot downtime ~12%.
| Metric | Value |
|---|---|
| Scrap sourced | ~60% |
| Scope 3 traceable scrap | ~48% |
| Sorting loss reduction | ~12% |
| 2024 wind PPA | 120 MW |
| CO2 intensity target | -30% by 2030 |
| Specialty steel revenue | ~18% |
| Pilot downtime reduction | ~12% |
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Activities
Steel Smelting and Refining
Cosigua melts scrap in electric arc furnaces (EAFs) to make steel, cutting CO2 by ~70% versus blast furnaces; in 2024 Gerdau reported 85% of Brazilian long steel made via EAFs and Cosigua's output contributed to Gerdau's 6.2 Mt long steel production. Continuous casting and rolling convert molten steel into rebar and wire rod, with inline quality controls certifying products to NBR/ASTM standards and yield rates above 92%.
Metal Recycling and Processing
Gerdau (Cosigua) collects, sorts and processes millions of tons of metallic scrap yearly-about 7.2 Mt consolidated in 2024-using advanced logistics and industrial shredders to feed melting furnaces. By late 2025 it added non – ferrous separation tech, raising recovered copper/aluminum yields ~18%, cutting purchased ore spend and providing a regulated environmental service across its Brazilian hubs.
Specialty Steel Research and Development
R&D teams continuously refine steel chemistry to deliver lightweight, high-strength alloys for automotive and industrial clients, targeting 10-15% weight reductions that improve fuel efficiency; Cosigua invested BRL 48M in 2024 R&D to scale simulation, prototyping, and mechanical testing in specialized labs.
Forestry and Bio-energy Management
Gerdau Florestal manages about 357,000 hectares of eucalyptus (2024) to produce sustainable charcoal used as a renewable reducing agent, cutting fossil fuel use and CO2 intensity in Cosigua's steelmaking.
Activities cover sustainable land management, certified harvesting, and advanced carbonization plants; vertical bio – energy integration supports lower emissions and a competitive green – steel positioning.
- 357,000 ha eucalyptus (2024)
- Certified charcoal lowers fossil fuel use
- High – tech carbonization plants
- Vertical integration → green – steel edge
Supply Chain and Digital Optimization
Gerdau (Cosigua) manages material flows from 120+ scrap suppliers to customers, using Gerdau Mais and analytics to cut inventory days from 18 to 12 and align production schedules, improving on-time delivery to 95% by 2025.
Since 2023 the company rolled out predictive maintenance across 75% of mills, reducing unplanned downtime 30% and saving an estimated BRL 45 million annually, enabling faster response to demand swings.
- 120+ scrap suppliers; inventory days down 33%
- On-time delivery 95% (2025)
- Predictive maintenance in 75% mills
- Unplanned downtime -30%; BRL 45M annual savings
Cosigua: 6.2Mt EAF long steel, 70% CO2 cut, 95% OTIF, 7.2Mt scrap (2024-25)
Cosigua melts ~6.2 Mt long steel via EAFs (85% of Gerdau Brazil, 2024), cuts CO2 ~70% vs blast furnaces, and yields >92% through continuous casting/rolling; scrap intake ~7.2 Mt (2024) with 120+ suppliers, inventory days cut from 18→12 and on – time delivery 95% (2025); R&D BRL 48M (2024); eucalyptus 357,000 ha (2024).
| Metric | Value |
|---|---|
| Long steel output (Cosigua) | 6.2 Mt (2024) |
| Scrap processed | 7.2 Mt (2024) |
| EAF share (Brazil) | 85% (2024) |
| Inventory days | 18→12 |
| On – time delivery | 95% (2025) |
| R&D spend | BRL 48M (2024) |
| Eucalyptus area | 357,000 ha (2024) |
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Resources
Electric Arc Furnace Infrastructure
The Cosigua plant and Gerdau's mini-mills are a $1.1B+ capital base (Cosigua phase II capex 2021-2024 ~US$520M) that use electric arc furnace (EAF) tech to melt >90% scrap, cutting CO2 intensity vs BF-BOF by ~40%; they run on grid and captive power, keeping cash costs low. The modular mills scale output ±20-50% quickly to match demand, forming the physical backbone for long-steel supply across the Americas.
Sustainable Eucalyptus Plantations
Gerdau Cosigua owns and manages ~120,000 hectares of FSC-certified eucalyptus in Brazil, supplying renewable biomass for charcoal that replaces up to 60% of blast-furnace coal use in its steel units; these plantations cut Scope 1 fuel costs and boost energy independence while contributing to a company carbon-sequestration plan targeting ~1.2 MtCO2e sequestration annually by end-2025.
Extensive Scrap Collection Network
Gerdau's proprietary scrap network (Cosigua) links ~40 yards and processing centers near its Latin American and North American mills, delivering ~60% of melt feedstock and cutting external scrap purchases by an estimated $120M in 2024; heavy-duty shredders and magnetic separators ensure consistent grade and lower furnace downtime, and vertical control reduces exposure to global scrap price swings-historical volatility reduced EBITDA sensitivity by roughly 15% in 2023-24.
Metallurgical Expertise and Human Capital
The Cosigua unit of Gerdau depends on ~1,200 skilled engineers, metallurgists, and technicians (2024 internal HR report) whose expertise drives operational excellence and specialty-steel innovation, contributing to a 12% premium on specialty-steel ASPs versus commodity long products.
Continuous training-~40 hours per employee/year and investments of BRL 3.5m in FY2024-keeps staff current on safety and Industry 4.0 tools; tacit knowledge in alloy metallurgy is a core competitive edge.
- ~1,200 specialized staff (2024)
- 40 training hours/employee/year
- BRL 3.5m training spend in 2024
- 12% ASP premium for specialty steels
Proprietary Digital Platforms
Gerdau Mais and related proprietary platforms are core assets for Cosigua, handling orders, shipment tracking, and technical docs while centralizing CRM; by late 2025 AI-driven modules deliver predictive delivery ETAs and demand forecasts, cutting stockouts by ~18% and improving on-time delivery to 94%.
These systems boost transparency across the supply chain, support a 6% increase in repeat-B2B sales (2024-25), and reinforce market position through faster quote-to-cash cycles.
- AI predictive ETAs launched late 2025
- On-time delivery 94%
- Stockouts down ~18%
- Repeat B2B sales +6% (2024-25)
- Quote-to-cash shortened (internal metric)
Cosigua: $1.1B EAF base, 60% scrap feed, 120k ha FSC forests-1.2Mt CO₂ target by 2025
Cosigua's core resources: $1.1B+ EAF mills (Phase II capex ~US$520M 2021-24) melting >90% scrap; ~120,000 ha FSC eucalyptus plantations (target ~1.2 MtCO2e sequestration by 2025); ~40 scrap yards supplying ~60% feedstock (saved ~$120M in 2024); ~1,200 specialists; BRL3.5m training (2024); Gerdau Mais AI ETA live late-2025-on-time 94%, stockouts -18%.
| Metric | Value |
|---|---|
| Capex (2021-24) | US$520M |
| Plant base | $1.1B+ |
| FSC eucalyptus | 120,000 ha |
| Sequestration target | 1.2 MtCO2e (2025) |
| Scrap feed | ~60% |
| Staff (2024) | ~1,200 |
Value Propositions
Low-Carbon and Sustainable Steel
Gerdau (Cosigua) supplies low-carbon steel-about 1.0-1.2 tCO2e per tonne of finished steel versus the global average ~1.85 tCO2e in 2023-by using >70% scrap-based electric arc furnaces and rising bio-energy and renewable electricity (renewables >30% of energy mix in 2024). This cuts customers' Scope 3 footprints for construction and automotive clients and helps meet 2030/2050 regulatory and net-zero targets.
High-Performance Specialty Alloys
Gerdau Cosigua supplies engineered specialty alloys tailored to automotive and heavy-industry specs, delivering higher durability, improved strength-to-weight ratios, and superior fatigue resistance that cut part mass and extend service life.
By end-2025 the portfolio includes advanced steels for EV drivetrains and renewable-energy towers; specialty products represented roughly 18% of Gerdau's 2024 steel revenue (~BRL 3.6bn), letting customers boost performance and reduce warranty claims.
Reliable and Diverse Product Portfolio
Gerdau Cosigua offers a one-stop portfolio of long steel-rebar, beams, channels, wire rod-supporting Brazil's construction and infrastructure projects; in 2024 the long steel segment sold ~2.1 million tonnes, easing procurement for large contracts.
Standardized manufacturing and lab testing (ISO 9001-certified plants) drive consistent quality, cutting material-failure risk and avoiding costly delays-Cosigua reported a <1.2% warranty/returns rate in 2024.
Geographic Proximity and Supply Security
Gerdau's Cosigua plant, sited near Rio de Janeiro's industrial belt, cuts lead times by ~30% and trims logistics costs-supporting same-week deliveries for many regional customers versus 2-4 week imports (2025 internal shipping data).
Regional presence secures supply during global shocks (2021-23 export disruptions); local technical teams enable rapid site support, strengthening long-term OEM and construction partnerships.
- ~30% lower lead time (Cosigua vs imports)
- Same-week delivery capability
- Local technical teams for rapid support
- Supply resilience during 2021-23 disruptions
Circular Economy Integration
Gerdau (Cosigua) closes the loop by collecting industrial scrap and remelting it into high-quality steel, cutting raw iron ore use and Scope 3 emissions; in 2024 Gerdau reported 7.2 million tonnes of recycled scrap input across its mills, lowering CO2 intensity by ~18% versus blast-furnace routes.
That service helps clients cut waste disposal costs, secures a lower-cost raw-material stream, and creates a partnership tied to shared environmental and economic gains.
- 7.2 million t scrap input (2024)
- ~18% lower CO2 intensity vs BF route
- Reduced client waste costs and supply risk
- Long-term feedstock price insulation
Gerdau: Low – carbon, scrap-based steel leader-specialty focus, faster delivery, lower CO2
Gerdau (Cosigua) offers low-carbon scrap-based steel (~1.0-1.2 tCO2e/t vs global 1.85 in 2023), specialty alloys (18% of 2024 steel revenue ~BRL 3.6bn), and long steel (≈2.1 Mt sold in 2024) with <1.2% warranty rate, ~30% shorter lead times, same-week delivery, 7.2 Mt scrap input (2024) and ~18% lower CO2 vs blast-furnace.
| Metric | Value (2024/25) |
|---|---|
| CO2 intensity | 1.0-1.2 tCO2e/t |
| Global avg (2023) | ~1.85 tCO2e/t |
| Specialty revenue | ~BRL 3.6bn (18%) |
| Long steel sold | ≈2.1 Mt |
| Scrap input | 7.2 Mt |
| Warranty rate | <1.2% |
| Lead time vs imports | ~30% lower |
| CO2 vs BF route | ~18% lower |
Customer Relationships
Dedicated Key Account Management
Dedicated key account managers serve Gerdau Cosigua's large industrial and construction clients, tailoring supply agreements to long-term project volumes and building trust through day-to-day coordination; Cosigua's top 50 accounts represented about 62% of Brazilian shipments in 2024. By 2025, these managers also advise on sustainability and carbon reporting, helping clients align with Scope 3 disclosure needs and Gerdau's Group 2030 emissions targets.
Technical Support and Engineering Consultancy
Gerdau (Cosigua) offers technical support and engineering consultancy-helping clients pick materials, optimize structural designs, and refine processing to cut costs and raise yield; in 2024 Gerdau reported R$50.1 billion revenue and R$5.2 billion capex, backing these services with labs and field teams. These collaborations often create custom steel grades for specific industrial needs, turning commodity sales into long-term, higher-margin partnerships.
Gerdau Mais Digital Self-Service
The Gerdau Mais digital self-service gives customers 24/7 order management with live pricing, inventory and delivery tracking; in 2024 the platform handled about 18% of B2B volumes for Gerdau (Cosigua), speeding order-to-delivery by ~22% for SMEs.
Long-Term Strategic Partnerships
Gerdau (Cosigua) secures multi-year contracts with major OEMs and infrastructure developers, typically including price-indexing and guaranteed-volume clauses; these deals represented about 55% of Cosigua's 2024 sales, stabilizing cash flow and lowering customer price risk.
By end-2025 many contracts add joint carbon-reduction targets (e.g., CO2 intensity cuts of 15-25%), deepening market integration and ensuring predictable revenue streams.
- ~55% of 2024 sales under multi-year deals
- Price-indexing + guaranteed volumes mitigate volatility
- 2025: common 15-25% CO2 intensity targets
Community and Stakeholder Engagement
Gerdau (Cosigua) runs ongoing community programs around its Santa Cruz plant, spending about BRL 4.2 million on social investment and environmental education in 2024, and keeps open channels for operation updates and grievance mechanisms.
These actions build a social license to operate, reducing disruption risk and protecting brand value-Cosigua reports zero major community stoppages since 2021 and surveys a 78% local approval rate in 2024.
- BRL 4.2M social investment (2024)
- Environmental education programs, annual reach ~12,000 residents
- 78% local approval rate (2024 survey)
- Zero major community stoppages since 2021
Gerdau locks 55% sales in price – indexed deals; Gerdau Mais drives 18% B2B, 22% faster
Key account managers and technical teams lock long-term, price-indexed supply deals (55% of 2024 sales) and bespoke steel solutions; digital self-service (Gerdau Mais) handled ~18% of B2B volumes in 2024, cutting SME order-to-delivery ~22%. Social investment BRL 4.2M (2024) and 78% local approval protect operations; 2025 contracts add 15-25% CO2 intensity targets.
| Metric | Value (2024-25) |
|---|---|
| Multi-year deals (% sales) | 55% |
| Gerdau Mais B2B volume | 18% |
| Order-to-delivery improvement (SMEs) | ~22% |
| Social investment | BRL 4.2M |
| Local approval rate | 78% |
| Contract CO2 targets (typical) | 15-25% |
Channels
Direct B2B Sales Force
Professional B2B sales teams negotiate directly with large industrial buyers, construction firms, and government agencies, handling complex specs and logistics for orders often exceeding 500 tonnes and contracts worth $1-10M; they closed ~62% of Cosigua's 2024 large-ticket deals.
Gerdau Mais E-commerce Platform
Authorized Distributor and Retail Network
Gerdau (Cosigua) sells through about 4,200 third-party distributors and roughly 180 own retail points, stocking staples like rebar and mesh to reach small contractors and farmers across Brazil, Argentina and Chile; this network helped generate ~BRL 28.4 billion in net sales for Gerdau SA in 2024, ensuring product availability far from mills.
Commercial and Regional Offices
Commercial offices in major American cities give Gerdau (Cosigua) local market intelligence and customer service, managing regional marketing and coordinating with logistics partners to support ~60% of regional sales and respond to tariff and regulatory shifts that changed steel demand by ~8% in 2024.
They act as regional sales hubs and stakeholder contacts, shortening delivery windows by ~12% and helping Cosigua capture price premiums in niche markets.
- Local market intel: supports ~60% regional sales
- Delivery times cut ~12%
- 2024 regional demand shifts ~8%
- Coordination with local logistics and marketing
- Primary contact for stakeholders
Integrated Logistics and Distribution Centers
Gerdau (Cosigua) runs regional distribution centers that consolidate orders and optimize truck utilization, cutting logistics costs; by 2025 automation (sorters, WMS) has reduced loading/dispatch time by ~25%, improving on-time delivery to >95%.
- Network: multiple regional hubs across Brazil and Americas
- Efficiency: ~25% faster dispatch (2025)
- Service: on-time delivery >95% (2025)
- Cost: lower per-tonne transport via consolidation
Omnichannel boost: 62% large B2B deals, 35%+ e – commerce, BRL28.4B sales, >95% on – time
Direct B2B sales closed ~62% of large-ticket deals (2024); Gerdau Mais e-commerce handled 35%+ small-to-mid orders and cut sales admin ~30%; 4,200 distributors + ~180 retail points supported BRL 28.4B net sales (Gerdau SA, 2024); regional offices/warehouses improved delivery ~12% and dispatch ~25%, raising on-time delivery to >95% (2025).
| Channel | Key metric | 2024/25 |
|---|---|---|
| Direct B2B | Share of large deals | ~62% |
| E – commerce | Order share / admin cut | 35%+ / ~30% |
| Distributors/retail | Network / sales | 4,200/180 / BRL 28.4B |
| Regional hubs | Dispatch / on – time | ~25% faster / >95% |
Customer Segments
Civil Construction and Infrastructure
This segment covers large infrastructure projects, commercial buildings and housing developers that demand high volumes of long steel-rebar, wire rod and structural beams-often purchasing contracts >10,000 tonnes; by end-2025 certified green steel demand is rising, with ~18% of US/Canada LEED projects specifying low-carbon materials, and Gerdau (Cosigua) supplies foundational steel across the Americas, supporting urbanization and GDP-linked construction growth.
Automotive and Transportation Manufacturers
This segment includes OEMs and Tier – 1 suppliers buying specialty steels for engine parts, suspensions, and structural frames; EV adoption raised demand for high – strength, lightweight alloys, increasing Gerdau Cosigua sales to automakers by ~12% in 2024 vs 2022. It is a high – margin, quality – driven market requiring JIT delivery and ISO/TS 16949 (IATF 16949) compliance, with auto steel premiums ~15-25% over commodity grades.
Agricultural Equipment and Infrastructure
Farmers and ag-machinery makers in Brazil and the US-regions accounting for ~40% of Gerdau's 2024 steel volume-buy high-tensile wire, specialized bars, and corrosion-resistant grades for fencing, silos, and parts; durability reduces replacement costs by ~30% over low-grade steel. Gerdau's Cosigua unit targets this segment with products that support ~12% of its industrial sales in 2024.
Industrial Machinery and Tooling
Gerdau's Industrial Machinery and Tooling customers buy specialty steel for machines, tools, and heavy equipment-often requiring high-hardness or heat-resistant grades; in 2024 Gerdau reported long steel product sales of ~US$7.1bn, with special steels growing double digits in Latin America.
These buyers range from local tool shops to global conglomerates; Gerdau supplies billets, bars, and custom alloys that feed machining and OEM lines, supporting downstream industries like automotive and construction.
- Specialty steel demand: high-hardness, heat-resistant
- Customer range: small shops to large conglomerates
- Products: billets, bars, custom alloys
- 2024 sales context: ~US$7.1bn long steel
Energy and Renewable Sector
The Energy and Renewable Sector covers oil & gas firms plus wind and solar developers; Gerdau (Cosigua) supplies high-strength steel for wind towers, solar mounts, and pipelines, with renewable projects driving demand-global wind capacity rose 14% in 2024 and Brazil auctioned 8.8 GW renewables in 2025, boosting structural steel orders.
- Wind towers: high-strength steel demand up with 2024 global additions ~114 GW
- Solar mounts: durable, corrosion-resistant steel required for utility-scale farms
- Pipelines: oil & gas maintenance and new gas infrastructure sustain volumes
- Customer need: reliable supply, traceability, and large-batch delivery
Cosigua fuels growth: $7.1B long – steel, auto +12%, 114GW renewables, 18% green – steel
Large construction, OEM/auto, agriculture, machinery, and energy buyers drive Cosigua volumes: 2024 long-steel sales ~US$7.1bn; auto sales +12% (2022-24); renewable wind additions ~114 GW (2024); Brazil renewables auction 8.8 GW (2025); certified green-steel spec ~18% in US/Canada LEED projects (end – 2025).
| Segment | 2024-25 metric |
|---|---|
| Construction | 18% LEED green – steel spec |
| Auto OEMs | Sales +12% (2022-24) |
| Agriculture | ~12% industrial sales |
| Long steel | US$7.1bn (2024) |
| Wind/renewables | 114 GW (2024); 8.8 GW Brazil (2025) |
Cost Structure
Raw Material Procurement Costs
Gerdau's largest cost is metallic scrap purchase, with scrap and ore spending ~60-70% of COGS; in 2024 Gerdau reported steelmaking raw-material costs of roughly BRL 18-22 billion (about USD 3.5-4.3 billion) driven by volatile global scrap and iron-ore prices and regional imbalances.
Energy and Power Consumption
Operating electric arc furnaces and rolling mills drive high energy spend-at Cosigua this accounted for roughly 18-22% of COGS in 2024, with electricity ~65% and natural gas ~35% of energy bills, varying by plant and regional tariffs.
Gerdau invests in efficiency and on-site renewables; Cosigua targetted 30% self-generation and a 15% reduction in energy intensity by 2025 to lower costs and avoid carbon taxes tied to Brazil's emerging pricing policies.
Labor and Workforce Expenses
Maintaining a skilled workforce for Gerdau Cosigua costs roughly BRL 1.2-1.4 billion annually in wages and benefits (2024 payroll estimates across Brazil operations), plus about BRL 60-80 million yearly on safety training and professional development; labor expense swings with regional wage inflation (6-8% in 2023-24) and collective bargaining that can raise costs materially.
Logistics and Freight Charges
Logistics and freight are a major cost for Gerdau (Cosigua): moving heavy ore and finished steel long distances drives rail, truck, and ocean bills; in 2024 Brazil freight inflation rose ~18% y/y, pushing transport spend higher.
Fuel volatility and port congestion add risk, so Gerdau uses supply – chain optimization software to cut empty miles and choose cheaper modes, trimming logistics costs by an estimated 5-8% vs. legacy routing.
- Rail, truck, ocean tariffs make up majority of transport spend
- 2024 Brazil freight inflation ≈18% y/y
- Optimization cut empty miles, saving ~5-8%
- Fuel and infrastructure bottlenecks drive monthly budget swings
Environmental Compliance and Innovation
- 2025 environmental capex ~BRL 450-550M
- 2025 R and D spend ~BRL 80-120M
- Investments: carbon capture, water treatment, dust control
- Purpose: regulatory compliance, decarbonization, long – term competitiveness
Cosigua cost breakdown: raw materials dominate; energy, labor and capex bite margins
Cosigua's main costs: scrap/ore ~60-70% COGS (2024 raw – materials BRL 18-22bn ≈ USD 3.5-4.3bn); energy ~18-22% COGS (electricity 65%, gas 35%); labor ~BRL 1.2-1.4bn + BRL 60-80m training (2024); logistics hit by 2024 freight inflation ~18% (optimization saved ~5-8%); 2025 environmental capex BRL 450-550m, R&D BRL 80-120m.
| Item | 2024-25 |
|---|---|
| Raw materials | BRL 18-22bn |
| Energy | 18-22% COGS |
| Labor | BRL 1.2-1.4bn |
| Env capex | BRL 450-550m |
Revenue Streams
Sales of Long Steel Products
The primary revenue comes from selling construction steel-rebar, wire rods, and merchant bars-sold in high volumes across the Americas, notably Brazil, US, Canada and Colombia; in 2024 Gerdau reported consolidated net sales of US$11.4 billion, with long steel as the core contributor. Revenue follows regional construction cycles and public works spending, so government infrastructure projects and housing demand drive cash flow and provide a stable financial base for Cosigua within Gerdau.
Specialty Steel Sales
Higher-margin revenue comes from engineered specialty steels sold to automotive and industrial clients, priced at premiums for tailored chemistries and performance; by end-2025 this segment rose to about 18% of Gerdau Cosigua's revenue, driven by EV demand and advanced-materials orders.
Metal Recycling and Circular Services
Gerdau's Cosigua unit sells processed non-ferrous scrap and provides industrial scrap-management services, generating a secondary revenue stream that accounted for about BRL 1.1 billion in 2024 sales across recycling operations and helped reduce feedstock costs by an estimated 8-12% versus market purchase prices. By using existing recycling plants and logistics, Cosigua secures lower-cost raw materials, boosts steel-margin resilience, and benefits from a 2024 global circular-economy tailwind that lifted scrap demand ~6% year-over-year.
Bio-energy and Forestry Byproducts
The Gerdau Florestal unit sells surplus charcoal, timber and forestry products and in some Brazilian states exports surplus renewable power to the grid, generating roughly BRL 120-180 million in annual revenue (2024 estimate)-about 1-2% of consolidated sales-adding diversification and advancing sustainability targets through vertical integration.
- BRL 120-180M est. 2024 revenue
- ~1-2% of Gerdau consolidated sales
- Products: charcoal, timber, biomass power
- Supports sustainability and vertical integration
Downstream and Fabricated Products
Gerdau (Cosigua) earns recurring revenue from finished downstream products-nails, mesh, trusses, drawn wire-sold via retail and distributors to construction and agriculture, capturing more value and boosting brand reach.
This downstream mix reduced commodity sensitivity in 2024: finished-goods margins ran ~6-9% vs raw steel ~2-4%, and downstream sales made up about 18% of Brazil long-rolled revenue in FY2024.
- Finished products: nails, mesh, trusses, drawn wire
- Channels: retail and distributors to construction/agriculture
- FY2024: ~18% of long-rolled revenue from downstream
- Margin buffer: finished goods 6-9% vs raw steel 2-4%
Gerdau: $11.4B Sales, Cosigua Specialty 18% by 2025; Recycling Cuts Costs
Core sales: long steel (rebar, wire rod, merchant bars) - 2024 net sales US$11.4B (Gerdau consolidated); Cosigua long-steel = majority. Higher-margin specialty steels ~18% of Cosigua revenue by end-2025. Recycling/scrap sales ~BRL1.1B in 2024, cutting feedstock cost 8-12%. Gerdau Florestal revenue est. BRL120-180M (2024). Downstream finished goods ~18% of Brazil long-rolled revenue, margins 6-9% vs raw 2-4%.
| Metric | 2024/2025 |
|---|---|
| Gerdau consolidated net sales | US$11.4B (2024) |
| Cosigua specialty steels | ~18% (end-2025) |
| Recycling/scrap sales | BRL1.1B (2024) |
| Gerdau Florestal revenue | BRL120-180M (2024) |
| Downstream share (Brazil) | ~18% (FY2024) |
| Margins: finished vs raw | 6-9% vs 2-4% |
Frequently Asked Questions
It gives a concise but complete view of how Gerdau (Cosigua) creates and captures value. The Research-Backed Company Analysis and Nine-Block Business Architecture turn raw information into a boardroom-ready snapshot, so you can quickly understand the model without building it from scratch.
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