FM Global

Property Loss Prevention Data Sheets 7-21

January 2013
Page 1 of 13

ROLLING MILLS

Table of Contents
Page

1.0 SCOPE ..................................................................................................................................................... 2

1.1 Changes ............................................................................................................................................ 2
2.0 LOSS PREVENTION RECOMMENDATIONS ....................................................................................... 2
2.1 Construction and Location ............................................................................................................... 2
2.1.1 General .................................................................................................................................... 2
2.1.2 Reheat Furnaces ..................................................................................................................... 2
2.1.3 Rolling Mills ............................................................................................................................. 2
2.2 Occupancy ......................................................................................................................................... 2
2.3 Protection ........................................................................................................................................... 3
2.3.1 General .................................................................................................................................... 3
2.3.2 Rolling Mills ............................................................................................................................. 3
2.4 Equipment and Process .................................................................................................................... 6
2.4.1 Reheat Furnaces ..................................................................................................................... 6
2.4.2 Rolling Mills — General ........................................................................................................... 7
2.4.3 Hot Rolling ............................................................................................................................... 9
2.5 Human Factor .................................................................................................................................... 9
2.6 Ignition Source Control ...................................................................................................................... 9
3.0 SUPPORT FOR RECOMMENDATIONS ............................................................................................... 10
3.1 General ............................................................................................................................................ 10
4.0 REFERENCES ........................................................................................................................................ 11
4.1 FM Global ........................................................................................................................................ 11
APPENDIX A GLOSSARY OF TERMS ....................................................................................................... 12
APPENDIX B DOCUMENT REVISION HISTORY ....................................................................................... 13

List of Figures
Fig. 1a. Location of deluge protection for an individual rolling mill stand (longitudinal view) ...................... 4
Fig. 1b. Location of deluge protection for an individual rolling mill stand (transverse view) ....................... 4
Fig. 2. Dust cap for deluge sprinklers ......................................................................................................... 5
Fig. 3. Older-style edge stand drive motor arrangement ............................................................................ 8
Fig. 4. Direct-drive edge stand arrangement ............................................................................................... 8
Fig. 5 Sendzimir Mill (Z-Mill) ....................................................................................................................... 12

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7-21 Rolling Mills
Page 2 FM Global Property Loss Prevention Data Sheets

1.0 SCOPE
This data sheet covers steel rolling mill processes and their corresponding hazards. This document provides
suitable automatic fire detection, protection, and process interlock schemes for rolling mills.
This data sheet does not cover aluminum rolling mills. Refer to Data Sheet 7-64, Aluminum Industry, for
guidance on aluminum rolling mills.

1.1 Changes
This is the first publication of this document.

2.0 LOSS PREVENTION RECOMMENDATIONS

2.1 Construction and Location

2.1.1 General
2.1.1.1 Ensure critical electrical cables are not exposed to hot metals or radiant heat.
2.1.1.2 Locate transformers in accordance with Data Sheet 5-4, Transformers.
2.1.1.3 Do not locate lubrication oil or hydraulic oil systems within electrical control or motor control rooms.
2.1.1.4 Provide adequate cooling for electrical control and motor control rooms. Locate the fresh air-intake
to avoid warm air or rolling fluid mist from the mills.

2.1.2 Reheat Furnaces

2.1.2.1 Arrange reheat furnaces in accordance with Data Sheet 6-0, Elements of Industrial Heating
Equipment, Data Sheet 6-3, Induction and Dielectric Heating Equipment, and Data Sheet 6-10, Process
Furnaces.

2.1.3 Rolling Mills

2.1.3.1 Provide a 1-hour fire-rated masonry or plate steel fire barrier between the rolling mill and the drive
motors.
A less-desirable alternative is a noncombustible barrier (e.g., sheet metal) with a line of water spray nozzles
along the mill side of the wall. Arrange the nozzles to provide complete coverage of the wall. Provide heat
detection to activate the nozzles.
2.1.3.2 Locate oil tanks, storage, and filtration systems in a cutoff room or low-value detached building. Locate
and design the cutoff room in accordance with Data Sheet 7-32, Ignitable Liquid Operations.
2.1.3.3 Provide 2-hour rated fireproofing on all steel supports on tanks and equipment associated with
ignitable liquids, including the oil filtration system. Visually inspect the fireproofing on a regular basis to monitor
its integrity. Replace sections that are in poor condition as needed.
An alternative to fireproofing is to install water spray protection for the steel supports in accordance with
Data Sheet 7-32, Ignitable Liquid Operations.
2.1.3.4 Provide adequate drainage and containment for the rolling fluid tanks and filtration system. Design
the drainage and containment in accordance with Data Sheet 7-83, Drainage and Containment Systems for
Ignitable Liquids.

2.2 Occupancy
2.2.1 Use FM Approved industrial fluids for hydraulic mill equipment and non-ignitable rolling medium if
possible. If ignitable hydraulic fluids or rolling medium are used, protect the mill in accordance with Section
2.3.

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2.3 Protection

2.3.1 General
2.3.1.1 Protect grouped electrical cables in accordance with Data Sheet 5-31, Cables and Bus Bars.
2.3.1.2 Design the automatic fire protection system in accordance with Data Sheet 5-31, Cables and Bus
Bars, and Data Sheet 5-32, Electronic Data Processing Systems. Provide smoke detection within electrical
rooms, control rooms, motor rooms, computer rooms, and cable tunnels. Link the detectors to a constantly
attended location. If the rooms are critical to production, the smoke detection system may be supplemented
with an automatic fire protection system to limit fire damage.

2.3.2 Rolling Mills

2.3.2.1 Ceiling Protection

2.3.2.1.1 Provide automatic sprinkler protection at ceiling level as follows:
A. For wet systems, design the sprinkler protection to deliver 0.2 gpm/ft2 (8 mm/min) over the most
hydraulically remote 3000 ft2 (280 m2). For dry systems, design the sprinkler protection to deliver 0.2
gpm/ft2 (8 mm/min) over the most hydraulically remote 5000 ft2 (465 m2).
B. Use FM Approved standard response K11.2 (160) sprinklers with a temperature rating of 286°F (141°C).
C. Install the sprinklers on a 10 ft x 10 ft (3.0 m x 3.0 m) spacing.
D. Include a hose stream allowance of 500 gpm (1900 L/min) for a duration of 120 minutes.
2.3.2.1.2 Provide automatic sprinkler protection under walkways, mezzanines, and other obstructions in
accordance with Data Sheet 2-0, Installation Guidelines for Automatic Sprinklers.

2.3.2.2 Mill Stand Protection

2.3.2.2.1 Provide automatic deluge protection for mill stands that use ignitable rolling fluids as follows:
A. Design the deluge system to deliver a density of 0.3 gpm/ft2 (12 mm/min) over the entire protected area,
including but not limited to the areas listed below (refer to Figure 1):
1. Below exhaust hoods and plenum chambers (if applicable)
2. At the top of the roll stack, on both sides, and between individual stands for multi-stand units to
cover the roll stack and the inner sides of the stand frames, above the pass line
3. Below the pass line, on both sides of the roll stack, and between individual stands for multi-stand
units, to cover the roll stack and the inner sides of the stand frames, below the pass line
4. Above the rolling fluid collecting pan (if an ignitable rolling fluid is used).
5. Within cable and pipe channels between the mill and utilities and bulk liquid tanks, enclosed or
unenclosed.
6. Below any ancillary equipment (coiler, uncoiler, entry and exit roller tables) where combustible
deposits or residues can accumulate in areas shielded from ceiling sprinklers or from mill protection.
7. Over any hydraulic equipment and reservoirs located on the floor or top of the mill stands or above
the exhaust hood.
8. Over the roll bearings, hydraulic cylinders and actuators, and associated flexible hoses containing
lube oil or hydraulic fluid, on the sides of the mill (enclosed or unenclosed by movable panels/shutters)
and shielded from effective coverage from the ceiling sprinklers or from mill protection.
B. Provide a dust cap for all deluge sprinklers to prevent accumulations of dirt and oil entering the system
(see Figure 2).
C. Activate the automatic deluge system using a crossed zone system of heat detectors and/or UV/IR
triple spectrum detectors. Other arrangements are acceptable.

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Typical automatic
sprinkler

Typical deluge
nozzle

Hydraulic/lubrication Longitudinal View

reservoirs

Fig. 1a. Location of deluge protection for an individual rolling mill stand (longitudinal view)

Typical automatic
sprinkler

1 Hour fire
Typical deluge rated wall
nozzle

Oil recirculation tray

Hydraulic/lubrication Transverse View

reservoirs

Fig. 1b. Location of deluge protection for an individual rolling mill stand (transverse view)

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Rolling Mills 7-21
FM Global Property Loss Prevention Data Sheets Page 5

D. When automatic sprinklers or water spray nozzles are used to protect vertical surfaces, the area to
be taken into account is the area in the vertical plane.
E. Include a hose stream allowance of 500 gpm (1900 L/min) in the design.
F. Select the temperature rating of deluge sprinklers or nozzles based on maximum ambient temperature
foreseen on the press (at least 25°F [14°C] above maximum ambient temperature).

Fig. 2. Dust cap for deluge sprinklers

2.3.2.2.2 In cases where frequent small fires occur (such as on cold rolling mills using low flashpoint rolling
fluids), provide a CO2 system to supplement the water-based fire protection systems. Arrange the CO2
system to operate first, before the sprinkler system.
When CO2 protection is supplementing an automatic sprinkler system, the CO2 extinguishing system can
be manually or automatically actuated. The automatic sprinkler system must be automatically actuated.
2.3.2.2.3 Provide automatic sprinkler protection or deluge protection over all hydraulics packs on rolling mills
that use nonignitable liquids in accordance with Data Sheet 7-98, Hydraulics.
2.3.2.2.4 When a foam-water automatic sprinkler system is provided to supplement a wet-pipe automatic
sprinkler system, or as an alternative to emergency drainage, use the following design criteria:
A. Install the system in accordance with Data Sheet 4-12, Foam-Water Sprinkler Systems.
B. Design the sprinkler system in accordance with this data sheet (7-21) or the FM Approval listing density,
whichever is larger, over the full demand area.
C. Design the foam concentrate supply to provide the full sprinkler discharge (use actual discharge based
on water supply), plus any hose streams also arranged to provide foam discharge, for the following amount
of time:
1. 10 minutes in areas provided with fully adequate emergency floor drainage.
2. 20 minutes in areas with limited or no emergency floor drainage.
3. The duration of any spilling ignitable liquids where the potential release point is more than 3 ft (0.9
m) above the floor.

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7-21 Rolling Mills
Page 6 FM Global Property Loss Prevention Data Sheets

D. Include an exterior hose stream allowance of 500 gpm (1900 L/min).

E. Provide containment as recommended in this data sheet.

2.3.2.3 Oil Tanks and Filtration Systems

2.3.2.3.1 Provide automatic fire protection over rolling fluid bulk tanks and filtration systems using one of
the following options:
A. Water spray protection for oil tanks and filtration systems. Design the water spray system to deliver
0.3 gpm/ft2 (12 mm/min) over the entire oil tank and filtration system area. Including a hose stream
allowance of 500 gpm (1900 L/min) for a duration of 60 minutes. Use FM Approved water spray nozzles.
B. For ceiling heights of 40 ft (12 m) or less, provide sprinkler protection designed to deliver 0.3 gpm/ft2
(12 mm/min) over the most hydraulically remote 4000 ft2 (370 m2) area. Include a hose stream allowance
of 500 gpm (1900 L/min) for a duration of 60 minutes. Use FM Approved K 11.2 (160) sprinklers installed
on 10 ft x 10 ft (3 m x 3 m) spacing.
2.3.2.3.2 When a foam-water sprinkler system is provided to supplement a wet automatic sprinkler system,
or as an alternative to emergency drainage, use the design criteria in Section 2.3.2.2.4.
2.3.2.3.3 If the oil systems are located in a cutoff room that has been designed in accordance with Data
Sheet 7-32, Ignitable Liquid Operations, the water demand from the oil system can be excluded from the
total water flow needed.

2.3.2.4 Exhaust Equipment

2.3.2.4.1 Provide automatic sprinkler protection inside ductwork in accordance with Data Sheet 7-78,
Industrial Exhaust Systems. Locate the sprinkler pipe work on the outside of the ducts for easy maintenance
access. Provide corrosion protection for sprinklers within the ductwork, using corrosion-resistant sprinklers
or two thin polyethylene bags placed over the sprinklers. Ensure the sprinkler temperature rating is at least
50°F (10°C) above the normal operating environment within the ducts.
2.3.2.4.2 Provide automatic sprinkler protection over combustible equipment (hoods, scrubbers, fan housings,
etc.) capable of delivering 0.2 gpm/ft2 (8 mm/min) over 2000 ft2 (190 m2). Use FM Approved sprinklers with
a minimum K factor of 8.0 (115).

2.3.2.5 Water Supply

2.3.2.5.1 Provide a water supply able to deliver adequate water flow to ceiling-level sprinklers and mill-level
protection (if present) assuming all systems operate during a fire. Include the protection over the oil storage
and filtration system if it is not located in a separate fire area.
2.3.2.5.2 Provide fire detection around the mill and over areas where the ignitable liquid lines are routed to
their point of use. Interlock the fire detection to shut down the rolling mill in accordance with Section 2.4.2.

2.4 Equipment and Process

2.4.1 Reheat Furnaces

2.4.1.1 Design reheat furnaces in accordance with Data Sheet 6-0, Elements of Industrial Heating Equipment;
Data Sheet 6-3, Induction and Dielectric Heating Equipment; and Data Sheet 6-10, Process Furnaces.
2.4.1.2 Provide thermal insulation on ductwork exposed to high temperatures.
2.4.1.3 Provide guards for ductwork susceptible to mechanical damage.
2.4.1.4 Keep the area about the reheat furnace clear of combustibles.
2.4.1.5 Provide interlocks on all hydraulic systems to shut down the pumps and depressurize the system in
the event of a fire.
2.4.1.6 Provide spare parts for the combustion controls and safeguards for the reheat furnaces.
2.4.1.7 Undertake routine checks of the combustion safeguards in accordance with Data Sheet 6-10, Process
Furnaces.

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FM Global Property Loss Prevention Data Sheets Page 7

2.4.1.8 Periodically check the water-cooled cables on the reheat furnace for tightness.

2.4.2 Rolling Mills — General

2.4.2.1 Provide all of the following automatic interlocks to shut down the rolling mill:
A. Controlled stop. This is a manually triggered stop that will shut down the mill in a progressive manner.
These stops are entirely monitored through a programmable logic controller (PLC) or computerized
controls on the mill.
NOTE: A controlled stop is a shutdown that brings the mill to a complete stop as quickly as possible. Some
delay is expected in order to avoid damage from the sudden stopping of rotating equipment.
B. Emergency stop (fire stop). Also known as an E-Stop, this is both an automatically initiated stop (via
sprinkler flow or heat or flame detection) as well as manually operated via a manual E-Stop button at the
operator’s pulpit. An emergency stop is a more rapid shutdown of the rolling mill. Wire these interlocks
directly to the rolling mills controls. If the interlocks are controlled via the PLC, provide protection against
unauthorized modification of the program.
C. Fire protection run (start permissive). This interlock will ensure all fire protection is working prior to
operation of the mill.
2.4.2.2 Interlock the hydraulic fluid, lubrication oils, and rolling fluids to shut down and depressurize in the
event of automatic sprinkler activation or heat or flame detector activation at the rolling mill or oil systems.
Ensure the isolation control values on large pressure accumulators and rolling fluid pumps close when the
interlocks activate.
2.4.2.3 Interlock exhaust fans in fume collection systems to de-energize and arrange for dampers in ducts
to close in the event of sprinkler activation or heat detector activation.
2.4.2.4 Provide low-pressure interlocks for pressurized ignitable liquid systems to shut down the rolling mill
(refer to Data Sheet 7-98, Hydraulic Fluids, and Data Sheet 7-32, Ignitable Liquid Operations, for more
details).
2.4.2.5 Provide flexible steel hoses or rubber hoses with a braided steel cover for all flexible connections
between the rolling mill and ignitable liquid reservoirs (e.g., hydraulic fluids, lubrication oils, and rolling fluids).
2.4.2.6 Ensure the dirty rolling fluid inlet valve on the oil filtration system is a “fail safe” design that closes
under loss of power and in the event of a fire.
2.4.2.7 Design the oil filtration system so the filter stack cannot be opened for replacement of the filter media
if the rolling fluid inlet valve is not confirmed in the closed position.
2.4.2.8 Provide fire dampers in the exhaust ducts for each stand of the rolling mill. Place dampers as close
to the mill intake as possible and another just prior to the fume exhaust filter. Arrange the dampers to close
automatically upon activation of any of the fire protection systems within the mill area or by failure of the fusible
links on the dampers.
2.4.2.9 Provide adequate rolling mill spares, including but not limited to transformers, motors (or at least a
spare coil), diodes, thyristors, and DC circuit breakers.
2.4.2.10 Develop and implement a preventative maintenance program for all equipment in accordance with
FM Global data sheets (refer to Data Sheets 5-20, Electrical Testing; 13-7, Gears; and 9-0/17-0, Maintenance
and Inspection).
2.4.2.11 Provide spare parts for critical pieces of equipment, including but not limited to the following items
for rolling mills:
A. Older-style edge stands (see Figure 3): motors, rolls, shaft bearings, gears and bevel gears.
B. Newer-style edge stands (see Figure 4): motors, rolls, gears, and bearings.
C. Mill rolls and bearings: despite being a wear item on a mill, the rolls and bearings have a long delivery
time if they cannot be repaired or reworked.
D. Hot strip mills: all motors, gears, and bearings. Spares of everything is recommended due to the high
daily production values associated with the hot mill, the long lead time of most parts (minimum 3 to 4
month replacement time), and the cost of purchasing spares on a straight time basis is about half the cost

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Page 8 FM Global Property Loss Prevention Data Sheets

Roll Roll
Slab in edger stand

Reducer
gears

Pinion Motor

Bull
Pinion shaft

Bevel gears Bevel gears

Fig. 3. Older-style edge stand drive motor arrangement

Motor Motor

Roll Roll
Slab in edger

Fig. 4. Direct-drive edge stand arrangement

of purchasing them in an emergency situation. Consider providing a blank casting of key gears as this
will help shorten the lead time for fabrication.
E. Rolling mill motors and drive power supplies: one complete identical spare motor of each type. An
alternative is a spare motor of a generator that can be adapted to fit in the same place.
F. Rectifier transformer: one complete spare of equal rating.
2.4.2.11.1 An alternative to providing adequate spares is to provide a contingency plan for a breakdown event.
In order for the contingency plan to be a viable alternative, the lost production time must be considerably
less than the replacement time of the parts. Review the contingency plan on an annual basis.

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2.4.2.12 Ensure all spare parts are stored in a clean, dry location free of combustibles where they are not
exposed to impact or molten metals. Ensure protective coatings or wrappings (if needed) are in place to
prevent corrosion or deterioration.

2.4.3 Hot Rolling

2.4.3.1 Provide N+1 water pumps and accumulator tanks for the high-pressure water spray system on hot
rolling mills.
2.4.3.2 Conduct internal examinations of the de-scale accumulator tanks every 5 years. The frequency of
the internal examinations can be extended to every 7 years if past internal exams have been satisfactory.
2.4.3.3 Conduct NDE examinations on the de-scale accumulator tanks every 5 years.
2.4.3.4 Remove from service any de-scale accumulator tank that is not certified as a pressure vessel by
the ASME or equivalent organization (refer to Data Sheet 12-0, Applicable Pressure Equipment Codes and
Standards), or that has not undergone an internal examination in the last 5 years.
2.4.3.5 Maintain the gears associated with hot rolling mill stands in accordance with Data Sheet 13-07, Gears.

2.5 Human Factor

2.5.1 Undertake monthly housekeeping inspections. Keep a written record of the inspections.
2.5.2 Conduct regular cleaning of all areas around hot and cold rolling mills that use ignitable liquids or
water-based emulsions with ignitable liquid components as part of the rolling medium. Include the cooler
surfaces of the mill, nearby equipment, and the walls and roof of the building. Pay particular attention to
deposits on electrical equipment, lighting fixtures, bearings, and other hot surfaces. Include cleaning of pits,
trenches, cables, and piping tunnels.
2.5.3 Use nonignitable cleaning agents and techniques (e.g., steam or hot water under pressure, or dry ice
pellets)that do not introduce any additional fire hazards.
2.5.4 Develop an emergency response plan and update it annually. As part of each annual update, review
the overall mill or line plan and adjust the plan to reflect any changes. Ensure all operators are familiar with
the plan and review it at least once a year. Include the following in the plan, at a minimum:
A. Procedures for shut down of the lube oil pumps, hydraulic pumps, and rolling fluid pumps in the event
of a fire.
B. Instructions on how to manually activate the fire suppression systems associated with each specific
mill in case they fail to operate automatically.
C. Designate a person or persons on each shift who will immediately contact plant emergency response
personnel and/or the public fire service in the event of a fire.
D. Designate a person or persons on each shift who will verify that the fire suppression systems for the
mill in question have operated and are able to manually trip the system if needed and if safe to do so.
E. Designate a person or persons on each shift to shut down all of the electrical power, hydraulic units,
lube oil units, natural gas lines, and oxygen gas lines to the mill involved in the fire if safe to do so.
F. Verify exactly what the E-Stops for every mill will shut down (e.g., all electrical equipment, all lube oil
pumps, all hydraulic pumps, all fume exhaust ventilation fans).
G. Verify that all hydraulic systems with accumulators are automatically drained back to the reservoir tank
in an emergency event so there is no equipment with pressurized hydraulics.

2.6 Ignition Source Control

2.6.1 Ensure ignition sources are strictly controlled in the direct vicinity of rolling mills and in the associated
coolant and hydraulic fluid treatment and pumping areas.
2.6.2 Prohibit smoking within any building.

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2.6.3 Use a hot work permit system when hot work operations cannot be avoided. Refer to Data Sheet 10-3,
Hot Work Management. If hot work is being undertaken near or on the rolling mill, thoroughly clean (wash
down) the mill to remove any combustible deposits, and isolate the roiling fluid and hydraulic systems prior
to the hot work being started.
2.6.4 Provide appropriate electrically rated equipment in locations where ignitable liquids with flash points
at or below 100°F (38°C) are handled or stored, or where any ignitable liquid is heated above its flash point
(including possible ambient temperatures). Refer to Data Sheet 7-32, Ignitable liquid Operations, and Data
Sheet 7-29, Ignitable Liquid Storage in Portable Containers, for further information.
2.6.5 Ensure electrical wiring insulation is compatible with the type of coolant fluid being used on the rolling
mill. Refer to Data Sheet 7-31, Cutting Oils, and Data Sheet 5-1, Electrical Equipment in Hazardous
(Classified) Locations, for further details.

3.0 SUPPORT FOR RECOMMENDATIONS

3.1 General
After molten metal has been either poured into ingot molds or cast into slabs, blooms, or billets, it is considered
to be in a semi-finished form. Depending upon the product being made, the metal is next processed by rolling
it into a particular shape. This is done by rolling the semi-finished material on a hot mill, and sometimes on
a cold rolling mill after the hot mill process. Cold rolling is conducted when the temperature of the metal is
below the re-crystallization temperature (approximately 1000°F [538°C] for carbon steel).
Rolling is often a chain of separate operations that progressively re-form the metal to its desired end product
and metallurgical properties. Whether it is a hot rolling or cold rolling process, the rolling mill generally
deforms the material between cylindrical rotating rolls.
The hot rolling mill arrangement can vary widely depending on the products being manufactured and the
desired properties of the metals. Semi- finished products are first heated in a re-heat furnace until they are
red hot (approximately 2,200°F—2,600°F [1200°C—1400°C]).
There are various types of reheat furnaces, but they generally fall into two types: batch and continuous.
Reheat furnaces are usually installed in groups. The combustion safety devices on a reheat furnace should
be arranged as outlined in Data Sheet 6-10, Process Furnaces. Flame supervision may not be required due
to the high temperatures maintained within the furnace. In existing furnaces, safeguards may be lacking.
Close proximity of the reheat furnaces to one another can mean that if an combustion fuel-related explosion
occurs on one furnace, it may damage the combustion controls of the adjacent furnace. This makes spare
components for the combustion controls extremely important to help reduce potential downtime. Similarly,
testing of the combustion safeguards is crucial to helping identify potential problems.
As a hot slab approaches the roughing mill, it is blasted with high-pressure water spray (2500—3000 psi
[172—207 bar]) to remove surface scale. The system for providing the water pressure typically involves a
group of two or more multi-stage centrifugal pumps and one or more de-scale accumulator tanks (often called
accumulator bottles).
The rolls are driven by electric motors ranging from several hundred to several thousand horsepower (tens
to hundreds of kilowatts). Lubrication fluids are needed for the mill gear boxes and rotating rolls. Hydraulic
fluids are needed to help exert force on the rolls. The lubricating and hydraulic fluids in a rolling mill process
usually involve grease, petroleum-based lubricating oil, and hydraulic fluid that may be petroleum-based,
water-based with additives such as glycol, or synthetic solutions. The petroleum-based lubricating mediums
and hydraulic fluids generally have flash points ranging from 300°F to 550°F (150°C to 290°C).
Hot rolling normally uses water as a rolling medium on the mill stands.
Most cold rolling processes use some type of rolling fluid, although there are a few that do not use a rolling
medium (e.g., temper mills, skin pass mills). The rolling medium can be a water-oil emulsion, with less than
5% oil and the remaining content water. The oil and water mixture provides cooling and lubrication for the
rolling process. Other media could be kerosene or tallow.
Fume exhaust systems are often provided to remove the rolling medium vapor but are not 100% effective.
As a result, there are fugitive vapors that escape the fume exhaust system and migrate just beyond the actual
rolling area outside the mill and into the open building area. The vapor eventually condenses on cooler

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Rolling Mills 7-21
FM Global Property Loss Prevention Data Sheets Page 11

surfaces of the mill, nearby equipment, and the walls and roof of the building. The condensed water
evaporates into the air, but the flammable portion of the rolling medium does not. The remaining residue from
the condensed vapor results in a combustible film on all the above-mentioned surfaces.

4.0 REFERENCES

4.1 FM Global
Data Sheet 2-0, Installation Guidelines for Automatic Sprinklers
Data Sheet 4-12, Foam-Water Sprinkler Systems
Data Sheet 5-1, Electric Equipment in Hazardous (Classified) Locations
Data Sheet 5-4, Transformers
Data Sheet 5-20, Electrical Testing
Data Sheet 5-31, Cables and Bus Bars
Data Sheet 6-0, Elements of Industrial Heating Equipment
Data Sheet 6-3, Induction and Dielectric Heating Equipment
Data Sheet 6-10, Process Furnaces
Data Sheet 7-31, Cutting Oils
Data Sheet 7-32, Ignitable Liquid Operations
Data Sheet 7-64, Aluminum Industry
Data Sheet 7-83, Drainage and Containment Systems for Ignitable Liquids
Data Sheet 7-78, Industrial Exhaust Systems
Data Sheet 7-98, Hydraulic Fluids
Data Sheet 7-104, Metal Treatment Processes
Data Sheet 9-0/17-0, Maintenance and Inspection
Data Sheet 10-3, Hot Work Management
Data Sheet 12-0, Applicable Pressure Equipment Codes and Standards
Data sheet 13-7, Gears

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Page 12 FM Global Property Loss Prevention Data Sheets

APPENDIX A GLOSSARY OF TERMS

Cobble: A controlled stop on a hot rolling mill.
Continuous Mill: The product passes only once through the mill.
Edging Mill: The edging mill (or edger) shapes the sides of the slab using two vertical rolls. The edger rolls
and sizes the side face of the slab and breaks loose scale from the edges.
Finishing Mill: Takes the rough shape and turns it into a finished hot rolled product. This product can either
leave the plant at this stage or continue to be further reduced using cold rolling processes.
FM Approved: The term “FM Approved” is used to describe a product or service that has satisfied the criteria
for Approval by FM Approvals. Refer to the Approval Guide for a complete list of products and services that
are FM Approved.
Mill Stand: A section of the mill housing one set of rolls.
Plate Mill: These mills produce plate products. Plate mills can be either universal mills or sheared plate mills
(discreet or individual plates).
Primary Mill: A mill that handles ingots only.
Reversing Mill: The product is passed back and forth through the same mill. Reversing mills can be used
to work slabs, heavy plate, or finished products.
Roughing Mill: The first operation in the hot milling process. The roughing mill (or rougher) takes the ingot
or cast product and further reduces it into the “rough” shape of the product via vertical force. These mills are
usually reversing mills.
Sendzimir Mill (Z-Mill): A cold rolling mill used in the processing of specialty metals such as stainless steel,
silicon steel, Titanium, Zirconium and Beryllium. The rolls on a Z-mill are arranged in a cluster as shown
in Figure 5. Z-mills can be arranged to be single pass or reversing mills.

Backing bearings Heavy, single block housing

Saddles
2nd intermediate
rolls

B C

A D

1st intermediate Driven rolls

rolls Work rolls

H E

Driven rolls G F

PRINCIPLE OF ROLL ARRANGEMENT AND SUPPORT

IN A SENDZIMIR MILL

Fig. 5 Sendzimir Mill (Z-Mill)

Steckel Mill: Uses two coils of sheet steel to feed the sheet back and forth through the mill, rather than driving
it through with the rollers. If a steckel mill is being used in hot rolling, a furnace is located at each end to

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Rolling Mills 7-21
FM Global Property Loss Prevention Data Sheets Page 13

help maintain the steel at the desired temperature. There are no furnaces present if the steckel mill is being
used for cold rolling. Steckel mills are commonly used for stainless or acid-resistant grade steel, nickel and
cobalt alloys, or titanium alloys.
Strip Mill: Produces hot rolled sheet. In general, these mills consist of a reversing rougher and multiple
finishing mill stands. Upon exiting the last finishing mill stand, the sheet is wound into coils. A strip mill can
also be arranged so the metal passes only one way through the mill. If this arrangement is being used there
are normally multiple stands arranged far apart for the metal to pass through. This type of arrangement was
very popular in the 1970s.
Tandem Mill: The metal passes through the mill only one way. As the metal passes from one mill stand to
the next, the thickness of the metal is incrementally reduced. The number of stands in a tandem mill can range
from 2 to 18. A tandem mill can be used in both hot and cold rolling.
Universal Mill: Is a combination of a roughing mill and edging mill, which uses both vertical and horizontal
to shape the metal.
Wreck: A controlled stop on a cold rolling mill.

APPENDIX B DOCUMENT REVISION HISTORY

January 2013. This is the first publication of this document.

©2013 Factory Mutual Insurance Company. All rights reserved.