Washington, D.C. — New analysis from Industrious Labs finds that steel and coke production linked to U.S. automaking contributes to an estimated 276 to 535 premature deaths, based on EPA modeling. The findings come as automakers face mounting pressure to meet climate commitments, align with evolving consumer expectations, and decarbonize supply chains.

The analysis focuses on coal-based steelmaking by major producers Cleveland-Cliffs and U.S. Steel, which together operate multiple blast furnaces and are supported by associated coke plants. Approximately 60% of U.S. primary steel is used in the automotive sector. This analysis applies that share uniformly across production volumes at Cleveland-Cliffs and U.S. Steel facilities, including associated coke operations, to estimate the following auto-linked health impacts:

• Up to 276–535 premature deaths
• 266 emergency room visits for respiratory issues
• 150,302 asthma symptoms
• 27,154 work loss days
• 31,416 school loss days

Pollution from coal-based steelmaking, including sulfur dioxide, nitrogen oxides, and fine particulate matter, has been linked to asthma, heart disease, cancer, and premature death. While actual health impacts vary by location and other factors, the analysis provides a national estimate of the toll this pollution takes when steel is used in the auto supply chain.

“As one of the largest drivers of demand for coal-based steel, the auto industry has both the responsibility and the leverage to lead the shift to cleaner steel,” said Maricela Gutierrez, Senior Campaign Strategist at Industrious Labs. “The data is clear, the technological alternatives are ready and consumer demand is growing. The automaker that leads will not only set a new standard, but gain a competitive edge.”

These shifts have significant implications for decarbonizing vehicle manufacturing. Steel remains one of the largest sources of embedded emissions in cars, but alternatives to coal-based steelmaking, such as hydrogen-based direct reduced iron (DRI) and electric arc furnaces (EAFs), offer viable pathways to phase out coal while maintaining performance and quality. While the transition will require planning and investment from automakers, the added cost per vehicle remains relatively modest: ICCT estimates a green steel premium of $199 per vehicle, or about 0.66% of a $30,000 MSRP.

History has repeatedly shown automakers can drive industry-wide transformation, such as the widespread adoption of lightweighting strategies following the 2008 fuel economy standards. Today, clean steel presents a similar opportunity to lead supply chain innovation and meet evolving consumer expectations, while slashing pollution-related illness in steel communities.

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Methodology

Industrious Labs conducted this analysis using the EPA’s Co-Benefits Risk Assessment (COBRA) screening model and the latest available emissions data from the National Emissions Inventory (2020). It applies the same methodology as the 2024 report Dirty Steel, Dangerous Air, which found that pollution from just 17 coal-based iron and coke facilities results in up to 900 premature deaths and $13.2 billion in health-related costs in the U.S.

Given the lack of plant-level production data tied specifically to auto sales, the analysis assumes a uniform allocation of 60% of production to automotive use across all facilities. This includes coke plants associated with primary steel production.

About Industrious Labs

Industrious Labs is focused on scaling campaigns and building a movement to clean up heavy industry through network and capacity building, research and analysis, data-driven campaigns, and sharp communications.