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New Update: Healthcare Costs Increasing by Over 60% in Some States. Will you be impacted?

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Alcoa Retirees Face Rising Health Care Costs: Insights from Patrick Ray & Tyson Mavar

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Healthcare Provider Update: Healthcare Provider for Alcoa Alcoa has partnered with several healthcare plans to provide its employees with benefits, primarily utilizing the services of major health insurance providers. For many employees, Alcoa's health coverage encompasses offerings from companies like Anthem Blue Cross Blue Shield and Aetna, focusing on comprehensive coverage options that include medical, dental, and vision plans. Potential Healthcare Cost Increases for Alcoa in 2026 As we look ahead to 2026, healthcare costs are projected to rise significantly, primarily driven by increases in ACA marketplace premiums. Nationally, insurers are requesting median premium hikes of approximately 20%, with individual states seeing increases as high as 66%. The expiration of enhanced federal premium subsidies adds further pressure, potentially leading to a staggering 75% increase in out-of-pocket costs for many enrollees. For Alcoa employees, these factors will likely mean a reevaluation of healthcare spending and strategic planning to mitigate escalating out-of-pocket expenses in the coming year. Click here to learn more

'With health care inflation outpacing general costs, Alcoa employees should consider building personalized strategies that include HSAs and emergency reserves to help manage future medical expenses.' — Michael Corgiat, a representative of The Retirement Group, a division of Wealth Enhancement.

'As medical expenses continue to rise, Alcoa employees benefit from proactively incorporating health care costs into their retirement planning through customized approaches like HSAs and dedicated emergency funds.' — Brent Wolf, a representative of The Retirement Group, a division of Wealth Enhancement.

In this article we will discuss:

  1. How health care inflation impacts retirement planning for Fortune 500 employees.

  2. Strategies with Health Savings Accounts (HSAs) and emergency medical funds.

  3. The need for tailored planning to meet Medicare gaps and long-term care needs.

Managing retirement health care costs calls for thoughtful planning, especially as medical expenses continue to outpace general inflation. Yet, for Fortune 500 professionals approaching retirement, generic guidance often misses the mark. Patrick Ray and Tyson Mavar of The Retirement Group, a division of Wealth Enhancement, recommend a customized approach that factors in health care inflation, coverage choices, tax-efficient tools, and access to liquid funds for unexpected medical events.

Health Care Estimate for Retirees

According to the Fidelity Retiree Health Care Cost Estimate, a 65-year‑old retiring in 2025 may need approximately $172,500 saved to cover health and medical expenses during retirement—an increase of over 4% since 2024. 1  Notably, this estimate assumes enrollment in Medicare Parts A, B, and D and excludes the costs of long‑term care.

Of that estimate, 44% of the costs would go to Medicare Parts B and D premiums, 47% relate to standard out‑of‑pocket costs (such as co-payments and deductibles), and 9% would be needed to purchase prescription medications. 1

These trends are particularly concerning given that roughly 20% of Americans say they haven’t considered health care in retirement planning, while 17% haven’t taken any planning steps yet. 2

For its part, the Employee Benefit Research Institute (EBRI) notes that a 65‑year‑old couple with higher prescription drug expenses may need as much as $413,000 to have a 90% likelihood of covering their medical needs in retirement. 3

The Value of a Personalized Retirement Health Care Approach

In light of this data, Ray and Mavar recommend developing a retirement health care strategy tailored to each individual's situation, particularly for those at large employers like Fortune 500. Key components could include:

  • - Estimating expected medical needs

  • - Using Health Savings Accounts (HSAs)

  • - Keeping readily available funds for emergencies

  • - Aligning health care coverage with lifespan and income expectations

1. Estimating Your Health Care Budget

Although industry research offers a baseline for average health care costs, it does not consider the full range of medical expenses Alcoa employees could face post-retirement. For instance, if you factor in costs related to long-term care, estimates could balloon by an additional $26,000 to $127,750 per year. 4

Beyond long-term care, additional cost categories could include:

  • - Medicare premiums

  • - Prescription medications and co‑pays

  • - Services not covered by Medicare (e.g., dental, vision)

Ray and Mavar caution Fortune 500 professionals not to underestimate these figures when planning.

2. Gaps in Preparedness

With 17% of Americans having taken no action to plan for health care in retirement, Ray and Mavar emphasize treating health care planning as a central component—not an afterthought.

3. Making Full Use of HSAs

Ray and Mavar suggest consistently contributing to HSAs during working years. For instance, a 35‑year‑old contributing up to $4,300 annually and assuming a 7% return might accumulate over  $500,000  by age 65, including approximately  $140,000 in tax savings . Only about  30%  of HSA holders currently invest those balances.

In their recent webinar, ' Leveraging HSAs to Reduce Health Care Costs ,' Mavar described benefits such as tax‑free growth and withdrawals for qualified medical expenses for those with high‑deductible health plans.

4. Building an Emergency Medical Reserve

Unexpected diagnoses or emergencies can quickly drain resources. Mavar recommends a separate cash reserve—such as in a money market or high‑yield savings account—outside primary retirement accounts. This may help retirees handle health care shocks without impacting long‑term investments.

  • Broader Economic Landscape: Health Care Inflation and Trends

Health care spending is projected to continue rising. In a report published by federal actuaries, U.S. health care spending is expected to rise by 7.1% in 2025—well ahead of general inflation. 5  Reasons for this rise range from growing personal health care spending and hospital spending growth, to prescription drugs and physician services. As a result, health care expenses could account for 20% of U.S. GDP by 2033. 5

At the same time, many health care insurers report higher medical-loss ratios, indicating increased spending on care—including chronic disease management and mental health services—costs that could be passed down to retirees.

Key Recommendations for Retirement Health Care Preparation

  • As Mavar and Ray note, the $172,500 estimate for those retiring in 2025 is simply a starting reference point. Early retirement or long-term care needs could push your total higher.

  • If you are among the percentage of people who has not yet considered health care costs in your retirement planning, now is the time to start. By leveraging the triple tax advantages available through HSAs, putting aside sufficient reserves to address medical emergencies, and exploring individual strategies that take your personal coverage choices, retirement timing, and health conditions into account, you can build a safety net that considers your long-term health care spending needs.

Final Thoughts

Health care outcomes and personal circumstances vary widely—especially among long‑time Fortune 500 professionals. A tailored planning strategy—covering realistic spending projections, full use of HSAs, dedicated medical reserves, and thoughtful coverage choices—can help support a more predictable and manageable retirement journey.

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Sources:

1. Fidelity Investments. “ Fidelity Investments Releases 2025 Retiree Health Care Cost Estimate: A Timely Reminder for All Generations .” 30 July 2025.

2. Barron's. “ The Healthcare Tab for Retirees Keeps Growing. How to Prepare ,” by Elizabeth O'Brien. 30 July 2025.

3. EBRI. ' New Research Report Finds Projected Savings Medicare Beneficiaries Need for Health Expenses Increased Again in 2023 .' 29 Jan. 2024. 

4. Genworth. ' Genworth and CareScout Release Cost of Care Survey Results for 2024 .' 4 March 2025. 

5. Fierce Healthcare. “ CMS study: Healthcare spending likely to grow by 7.1% in 2025 ,” by Paige Minemyer. 30 June 2025.

What are the key eligibility requirements for employees to participate in the Pension Plan for Certain Hourly Employees of Alcoa USA Corp, and how do these requirements change if an employee is hired or rehired after April 1, 2022? This question aims to explore the specific criteria that must be met for participation in the plan, providing clarity on both the general eligibility for new employees and any exceptions for those previously employed.

Eligibility Requirements: Employees are automatically eligible for the Pension Plan for Certain Hourly Employees of Alcoa USA Corp if they were hired or rehired before April 1, 2022, have reached age 21, and completed one year of vesting service. Employees hired or rehired on or after April 1, 2022, are not eligible for this pension plan​(Alcoa USA Corp_Pension …).

How is the vesting service calculated in the context of the Alcoa USA Corp pension plan, and what implications does it have for an employee considering retirement? Understanding the nuances of how vesting service is accrued and the minimum time required to become vested can significantly impact an employee's retirement planning.

Vesting Service Calculation: Vesting service determines when an employee becomes eligible for pension benefits. Employees become vested after completing five years of vesting service, which includes both periods of pension service and non-pension service such as absences not counted towards pension service. This is crucial for retirement planning, as it ensures employees are entitled to pension benefits even if they leave the company after becoming vested​(Alcoa USA Corp_Pension …).

What various retirement options are available to employees of Alcoa USA Corp, and how do these options affect the benefits and payout structure for retiring employees? This question addresses the multiple choices employees face when planning their retirement, including the differences between normal retirement, early retirement, and disability retirement benefits.

Retirement Options: The plan offers normal retirement (at age 65 with five years of vesting service), 60/10 retirement (for employees between 60 and 62 with 10 years of vesting service), and 62/10 retirement (for employees between 62 and 65 with 10 years of vesting service). Disability retirement is also available for those permanently incapacitated with 10 years of vesting service​(Alcoa USA Corp_Pension …).

Can you elaborate on the survivor benefits provided under the Alcoa USA Corp pension plan, and what steps need to be taken to ensure that a spouse or partner is eligible for these benefits upon the employee's retirement? This question seeks to examine the protections and financial security afforded to survivors, alongside the required documentation and choices available to employees.

Survivor Benefits: The pension plan provides automatic surviving spouse coverage unless waived by the employee and spouse. Surviving spouse pensions are payable if the employee dies while actively employed and vested in the plan, after retirement, or while receiving a deferred vested pension. The spouse must submit a written application to claim benefits​(Alcoa USA Corp_Pension …)​(Alcoa USA Corp_Pension …).

What are the specific methodologies used to calculate the regular monthly pension for employees retiring under the Alcoa USA Corp pension plan, and how might these calculations vary based on an employee's age and years of service? This question looks at the complex actuarial factors that influence pension benefits, enhancing employees' understanding of how their retirement income is determined.

Pension Calculation: The regular monthly pension is calculated using a formula based on the employee's pension service and a pension factor in effect when pension service ends. For example, if an employee retires at 65 with 10 years of service, the pension factor might be $57 per year of service. The pension is adjusted based on age and service length​(Alcoa USA Corp_Pension …).

In the event of a disability, how does the Alcoa USA Corp pension plan provide support to affected employees, and what are the requirements to qualify for disability retirement benefits? This question emphasizes the importance of understanding disability provisions, ensuring employees are aware of their rights and the circumstances under which they might qualify for benefits.

Disability Retirement: Employees under 62 who are permanently incapacitated with at least 10 years of vesting service qualify for disability retirement. They must be deemed permanently disabled and unable to return to work in a bargaining unit occupation. A medical examination may be required to confirm ongoing eligibility​(Alcoa USA Corp_Pension …).

What steps must Alcoa USA Corp employees take to apply for retirement benefits, and what timelines are involved in the processing and payout of these benefits? This question delves into the procedural aspects of retirement applications, aiming to prepare potential retirees for the necessary actions they must undertake.

Retirement Application Process: Employees must file a retirement application with the plan administrator before their desired retirement date. The application can be filed up to 90 days before retirement, and the process typically includes receiving benefit explanations and payment elections within this timeframe​(Alcoa USA Corp_Pension …).

How does the Pension Benefit Guaranty Corporation (PBGC) influence the pension benefits received by employees of Alcoa USA Corp, particularly in the context of plan terminations or financial challenges? This question explores the security provided by the PBGC, focusing on its role as a backup for employees’ pension benefits.

Pension Benefit Guaranty Corporation (PBGC): The PBGC provides a safety net for pension benefits in the case of plan termination or financial distress. If the pension plan is underfunded, the PBGC ensures employees still receive pension benefits, although certain limitations may apply​(Alcoa USA Corp_Pension …).

What resources and support does Alcoa USA Corp provide to its employees for understanding their pension plan, and how can employees reach out for assistance regarding their retirement options? This question emphasizes the resources available to employees for further education and guidance, ensuring they know where to turn for help.

Resources for Understanding the Plan: Employees can access information about their pension plan and retirement options through the Alight Worklife™ website or by calling the Alcoa benefits helpline. These resources offer guidance on applying for retirement and understanding plan benefits​(Alcoa USA Corp_Pension …).

How can employees of Alcoa USA Corp contact the benefits management team to learn more about their specific pension plan details, and what channels are available for inquiries? Understanding the communication channels can empower employees to seek the information they need, facilitating a smoother transition into retirement.

Contacting Benefits Management: Employees can reach out to the benefits management team through the Alight Worklife™ website or by phone at 1-844-31ALCOA. This service provides assistance with pension-related inquiries and retirement applications​(Alcoa USA Corp_Pension …).

With the current political climate we are in it is important to keep up with current news and remain knowledgeable about your benefits.
Alcoa Corporation offers a defined benefit pension plan for certain retirees, known as the Alcoa Retirement Plan. In 2022, Alcoa transferred $1 billion in pension obligations to an annuity, maintaining benefit levels for retirees. Eligibility typically requires a combination of years of service and age. Alcoa also offers a 401(k) plan with a company match of up to 6% of employee contributions. Employees can make traditional and Roth contributions, with immediate vesting for all contributions. [Source: Alcoa Benefits Summary, 2022, p. 12]
Restructuring and Leadership Changes: Alcoa announced a significant restructuring of its Executive Leadership Team effective February 1, 2023, to enhance operational excellence, cost management, and innovation. Key changes include William F. Oplinger becoming EVP and Chief Operations Officer, Molly Beerman being appointed as EVP and Chief Financial Officer, and Renato Bacchi taking on added responsibilities as EVP, Chief Strategy & Innovation Officer. These changes aim to align the company's strategy with its vision to reinvent the aluminum industry and integrate corporate strategy with innovative technologies (Source: Alcoa Corporation). Layoffs and Operational Adjustments: Alcoa took a $6 million charge related to layoffs at its Kwinana alumina refinery in Australia, part of a broader restructuring program. This decision was driven by operational setbacks and permitting issues in Australia. Additionally, the company has reduced the number of planned layoffs at its Warrick Operations from an estimated 600 to about 325. This reduction reflects ongoing adjustments to improve efficiency and align with market conditions (Sources: Mining Weekly, Indianapolis Business Journal).
Alcoa provides stock options and RSUs as part of its equity compensation programs. Stock options allow employees to purchase company stock at a fixed price after a vesting period, while RSUs are awarded with a promise of company shares upon meeting certain conditions. In 2022, Alcoa granted both stock options and RSUs to employees, focusing on performance-based RSUs to drive long-term goals. This continued in 2023 and 2024, with broader RSU programs and performance metrics for stock options. Executives and management receive substantial portions of compensation in stock options and RSUs, promoting long-term commitment and performance. [Source: Alcoa Annual Reports 2022-2024, p. 45]
In 2022, Alcoa enhanced its healthcare benefits with expanded mental health support and telemedicine services. By 2023, the company continued to focus on employee wellness with additional preventive care options and wellness initiatives. In 2024, Alcoa's strategy remained centered on integrating innovative health solutions and maintaining comprehensive healthcare coverage. The company emphasized digital health tools and employee support programs to address evolving needs. Alcoa aimed to ensure robust healthcare benefits while managing costs effectively. Their approach reflects a commitment to improving overall employee well-being and satisfaction.
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For more information you can reach the plan administrator for Alcoa at 390 park avenue New York, NY 10022-4608; or by calling them at (412) 315-2900.

https://contracts.justia.com/companies/alcoa-corp-5547/contract/224382/ https://corporate.findlaw.com/contracts/compensation/amendment-to-deferred-compensation-plan-alcoa2.html https://cache.hacontent.com/ybr/R516/16557_ybr_ybrfndt/downloads/PriorAlcoaSalariedAFN.pdf - Page 23 https://cache.hacontent.com/ybr/R516/16557_ybr_ybrfndt/downloads/PlanIIC.pdf - Page 15 https://www.cityofalcoa-tn.gov/DocumentCenter/View/1511/2023-Benefits-Guide?bidId= - Page 30 https://cache.hacontent.com/ybr/R515/16557_ybr_ybrfndt/downloads/11AlcoaSavingsPlan.pdf - Page 42 https://s29.q4cdn.com/844074237/files/doc_news/2022/07/20220808_PensionAnnuity-VFinal.pdf - Page 8 https://www.alcoa.com/global/en/pdf/sustainability/policies-benefits.pdf - Page 5 https://www.alcoa.com/global/en/pdf/corporate-governance/2023-proxy.pdf - Page 10 https://www.alcoa.com/global/en/pdf/2022-annual-report.pdf - Page 50 https://www.alcoa.com/global/en/pdf/employee-handbook-2024.pdf - Page 35 https://www.alcoa.com/global/en/pdf/benefits-summary-2023.pdf - Page 18

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