Metal forgeries

‘Special risks’ include any site where its contents are either highly flammable and/or highly valuable and sensitive - in these cases the traditional automatic fire sprinklers are not enough to provide the level of protection needed. 

Special risk fire suppression systems must be uniquely designed to work under extraordinary conditions to protect both the workers and the facility from the potentially devastating consequences of fire.

Metal forging involves heating metals to high temperatures, often exceeding 1,000°C, which greatly increases the risk of fires and explosions. These high temperature processes involving molten metals and flammable materials all contribute to make standard fire suppression systems insufficient in protecting metal forgeries.

Complex operational environments working with combustible metals and molten metals (e.g., magnesium, titanium, aluminium) present fire risks that differ substantially from conventional fires. 

Challenges faced

• Heat detectors may struggle to differentiate between normal operational temperatures and an actual fire
• Flame detectors are sensitive to visible flames but might be delayed in detecting fires that start in less obvious ways, such as in confined spaces or under molten metal
• Fire alarms are raised falsely due to the sensitivity of fire suppression systems, disrupting operations and lead to unnecessary clean-up or system resets
• Improper calibration can result in either desensitised or over-sensitive systems that activate without a real fire threat, interrupting work and wasting resources
• Intense bright light and glare from molten metals can interfere with optical flame detectors.
• High temperature processes, including the presence of open flames, sparks, and molten materials, increases the potential for fires.
• Reactive materials - combustible metals like magnesium or titanium can ignite spontaneously in certain conditions and burn at very high temperatures, requiring early and precise detection.
• Rapid fire spread - fires involving combustible metals can spread quickly, producing extreme heat and potentially explosive reactions.

Our experience

A fully effective fire suppression system for metal forging operations requires the use of a deluge system together with specialised equipment and bespoke detection systems, designed to handle the unique risks posed. 

RFE have substantiated experience in providing such a solution for special risk forgeries. In 2023, following a history of fires around their steel forging machines our steelworks client wanted to protect them. The steelworks had no other form of fire suppression which could be extended to cover the fire prone areas. After carrying out site visits and research, RFE were able to provide our client with a hybrid / bespoke fire suppression solution to cover and protect its highly sensitive, fire prone areas.

System highlights

1. Finding a solution for the flame detector to differentiate between a genuine fire and the heat/ radiation from the workpieces (3000°C+ furnaces)
2. Working alongside Siemens, the FM approved flame camera manufacturer, we developed and programmed the detection system to deliver a workable solution – a first time in this type of environment.
3. Providing additional controls to shut down the forging machines hydraulic systems when the deluge system operates, to prevent fire spreading fire to areas not covered by the deluge system.
4. Carefully selecting and sourcing deluge system pipework, nozzles, bracketry for use within this challenging environment.
5. Installing a 530m³ water tank, sized to use the existing footprint of a discussed crane pad.
6. Working with the insurer we were able to engineer out the environmentally unacceptable foam requirement normally required to tackle an oil fire, instead providing additional sprinklers along the external building façade as an alternative solution. 
7. Establishing the 1 in 500-year flood level and building an elevated base to raise the pumphouse above this. The pump is deemed critical plant, required to be available at all times - flood concerns due to the proximity of the pumphouse to a major river put this requirement at risk.