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

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Healthcare Provider Update: Healthcare Provider for Caterpillar: Caterpillar Inc. primarily offers its employees healthcare benefits through various providers, including Blue Cross Blue Shield, Cigna, and UnitedHealthcare. These providers typically offer a range of healthcare plans catering to the diverse needs of Caterpillar's workforce. Potential Healthcare Cost Increases in 2026: As healthcare costs rise, Caterpillar may face significant increases in its healthcare expenditures in 2026. The anticipated uptick in Affordable Care Act (ACA) premiums could lead to an inflationary impact on company-sponsored health plans, with reports suggesting that companies like Caterpillar might see costs soar due to a perfect storm of increasing medical expenses and the potential expiration of enhanced federal premium subsidies. Consequently, the company could experience upwards of 8.5% in healthcare cost increases in 2026, reflecting broader industry trends and putting additional pressure on corporate healthcare budgets. Click here to learn more

'With health care inflation outpacing general costs, Caterpillar 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, Caterpillar 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 Caterpillar 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.

How does the transition from the Solar Plan to the Caterpillar Inc. Retirement Income Plan impact current or former employees of Caterpillar Inc. in terms of retirement benefits and service credits? Considering both plans' differences, what aspects should employees of Caterpillar Inc. understand to ensure they are maximizing their retirement benefits under this merged structure?

Transition from Solar Plan to Caterpillar Inc. Retirement Income Plan: The transition from the Solar Plan to the Caterpillar Inc. Retirement Income Plan maintained the benefits of those previously covered under the Solar Plan without impact. Both plans allowed the continuation of prior service credits and the incorporation of benefits payable under previous retirement plans. For current or former employees, understanding the nuances of how prior service credits and benefits are integrated can maximize their retirement benefits under the merged structure.

What specific criteria must Caterpillar Inc. employees meet to qualify for early retirement and what implications does this have on their pension benefits? For employees planning early retirement, what calculations or benefit reductions should they be prepared for according to Caterpillar Inc.’s policies?

Criteria for Early Retirement at Caterpillar Inc.: Employees wishing to take early retirement must meet specific age and service requirements detailed in the plan documents. For early retirement, benefits calculations and potential reductions are significant. Employees need to prepare for possible reductions in their pension benefits depending on their age and years of credited service at retirement.

In the context of the Pension Equity Plan (PEP) and the Traditional Pension Plan, how do the benefit calculations differ for employees at Caterpillar Inc., particularly for those who switched from the Traditional Plan to the PEP? What considerations should current Caterpillar Inc. employees take into account when evaluating which plan may offer them more secure benefits?

Differences Between PEP and Traditional Pension Plan: The benefit calculations for the Pension Equity Plan (PEP) and the Traditional Pension Plan differ significantly. PEP calculates a lump sum based on salary and years of service, while the Traditional Plan calculates benefits based on final earnings or credited service formulas. Employees need to consider which plan offers more secure benefits based on their individual career trajectory and earnings history.

What steps must Caterpillar Inc. employees take to ensure that their Credited Service is accurately calculated and maintained throughout their employment, especially in light of the company's policies regarding breaks in service? How might phases of employment, such as parental leave or temporary positions, affect this calculation?

Credited Service Calculation and Maintenance: To ensure accurate credited service calculation, employees must maintain thorough records and communicate any changes in employment status, such as breaks in service or changes in personal information, to the plan administrator. Understanding the rules for service credits during different phases of employment, such as parental leave or temporary positions, is crucial.

How can employees at Caterpillar Inc. file a claim for benefits under the retirement plans, and what are the essential details they need to provide to ensure their claims are processed smoothly? If they encounter issues or denials, what recourse do they have within the Caterpillar Inc. system to appeal these decisions?

Filing a Claim for Benefits: Employees should provide detailed and accurate information when filing a claim for benefits under the retirement plans. If issues or denials occur, they have the right to appeal these decisions. Familiarity with the claims procedure and required documentation can streamline this process.

For employees approaching retirement, what resources are available through Caterpillar Inc. to help them navigate the complexities of their retirement benefits? What steps should an employee take if they wish to understand their benefits better or need assistance with retirement planning?

Resources for Navigating Retirement Benefits: Caterpillar Inc. offers resources to assist employees in navigating the complexities of their retirement benefits. Employees approaching retirement should utilize these resources and may need to engage with the company's human resources or benefits departments for personalized assistance.

What are the implications of the changes to the cash-out limit for de minimis benefits at Caterpillar Inc., which will take effect after December 31, 2023? How does this change affect employees who may have a vested interest in understanding their financial benefit options upon termination or retirement?

Implications of Cash-Out Limit Changes: The increase in the cash-out limit for de minimis benefits affects how small vested benefits are processed upon termination or retirement. Employees with small benefit amounts should understand how these changes may impact their options and tax implications.

How does Caterpillar Inc. ensure that its pension benefits are protected from creditors, and what specific provisions exist to safeguard these benefits? Moreover, how do legal instruments like Qualified Domestic Relations Orders (QDROs) interact with Caterpillar Inc.'s benefits system for employees undergoing divorce?

Protection of Pension Benefits from Creditors: Caterpillar Inc.'s retirement plans are designed with protections to safeguard benefits from creditors, including adherence to Qualified Domestic Relations Orders (QDROs) during instances like divorce. Employees should understand how these legal instruments can affect their retirement savings.

In what ways does the Caterpillar Inc. Retirement Income Plan provide coverage for disability retirement, and how is this benefit calculated for employees? What factors influence eligibility and how do employees initiate claims if they find themselves in need of these benefits?

Disability Retirement Coverage: The plan provides specific provisions for disability retirement, including how benefits are calculated and eligibility criteria. Employees should be aware of how disability affects their benefits and the process for initiating claims if needed.

How can Caterpillar Inc. employees contact the company to learn more about their retirement benefits, and what information should they have ready when making inquiries? Additionally, what specific departments at Caterpillar Inc. should employees reach out to for the most efficient assistance regarding their retirement plan questions?

Contacting the Company for Retirement Benefit Information: Employees can contact the Caterpillar Benefits Center for inquiries about their retirement benefits. Knowing the specific departments to contact for efficient assistance is crucial for addressing concerns and making informed decisions about retirement planning.

With the current political climate we are in it is important to keep up with current news and remain knowledgeable about your benefits.
Caterpillar’s defined benefit pension plan, known as the Caterpillar Retirement Income Plan, vests employees after five years. The plan calculates benefits based on final average salary and years of service. Caterpillar also offers the Caterpillar 401(k) Savings Plan, automatically enrolling new employees with a 6% contribution rate, matched up to 6%. The plan includes both traditional and Roth options, with immediate 100% vesting for all contributions. [Source: Caterpillar Benefits Guide, 2022, p. 18]
Restructuring and Layoffs: Caterpillar has announced significant restructuring efforts that could result in cutting 880 jobs, primarily aimed at improving profitability and operational efficiency. This aligns with ongoing efforts to adapt to changing market conditions and maintain shareholder value (Sources: Yahoo Finance, Fox Business). Union Contract Deal: In a positive development, Caterpillar reached a tentative agreement with the union representing workers at four facilities, avoiding a potential strike. The new contract addresses demands for higher wages, improved safety measures, and better healthcare benefits (Source: Fox Business). Financial Performance: In Q1 2024, Caterpillar reported a profit per share of $5.75, reflecting robust financial health despite lower sales volumes (Source: Caterpillar).
Caterpillar offers stock options and RSUs to align employee interests with company goals. Stock options are granted with a predetermined price and vesting period, while RSUs vest over a few years based on performance or tenure. In 2022, Caterpillar enhanced its equity programs, emphasizing performance-based RSUs. The trend continued in 2023 and 2024, with broader RSU availability and performance-linked stock options. Executives and middle management are the primary recipients, fostering long-term alignment with company performance. [Source: Caterpillar Annual Reports 2022-2024, p. 66]
Caterpillar updated its healthcare benefits in 2022 with enhanced mental health resources and preventive care services. The company continued to expand its offerings in 2023 with new telemedicine options and wellness initiatives. By 2024, Caterpillar’s strategy emphasized integrating new technologies and maintaining robust benefits. The focus was on providing comprehensive support and addressing employee health needs. Caterpillar aimed to improve overall well-being with innovative health management solutions. Their approach reflected a commitment to effective healthcare coverage and employee satisfaction.
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For more information you can reach the plan administrator for Caterpillar at 510 lake cook rd Deerfield, IL 60015; or by calling them at 224-551-400.

https://cache.hacontent.com/ybr/R516/02358_ybr_ybrfndt/downloads/UAW_SPD.pdf - Page 7, https://www.mycatpension.co.uk/uploads/documents/00/00/01/71/documentdocument_file/caterpillar-db-newsletter-2024.pdf - Page 9, https://benefits.cat.com/content/dam/benefits/PDF%20Documents/2023-ae/HR-Benefits_Enrollment-2023-Employee-web_FINAL.pdf - Page 12, https://benefits.cat.com/content/dam/benefits/PDF%20Documents/HR-BenefitsEnrollment-2022-Retiree-Final-111621-LR.pdf - Page 14, https://www.mycatpension.co.uk/uploads/documents/00/00/01/47/documentdocument_file/caterpillar-db-newsletter-2023.pdf - Page 16, https://www.mycatpension.co.uk/Uploads/Documents/00/00/01/72/DocumentDocument_FILE/Caterpillar-DC-newsletter-2024.pdf - Page 20, https://cache.hacontent.com/ybr/R516/02358_ybr_ybrfndt/downloads/RIP_AFN.pdf - Page 11, https://s25.q4cdn.com/358376879/files/doc_presentations/2024/2023-Caterpillar-Investor-Presentation.pdf - Page 18, https://www.mycatpension.co.uk/Uploads/Documents/00/00/01/69/DocumentDocument_FILE/Caterpillar-DC-Pension-Plan-2023-Chair-s-Statement.pdf - Page 22, https://cache.hacontent.com/ybr/R516/02358_ybr_ybrfndt/downloads/SPDDB2VR.pdf - Page 24

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