Abstract Controlling the hot rolling process requires a deep understanding of the underlying metallurgical phenomena. Quantitative methods are of paramount importance for achieving the capability of controlling microstructural evolution. Since the final mechanical properties of steel result from microstructural evolution in the whole process, analysis of the microstructure provides an important input for numerical simulations that can be used for tailoring the mechanical properties of steel. The evolution of grain size distribution of a low-carbon CrNiMnB ultrahigh-steel in austenitic state is studied in hot forming and annealing using experimental data obtained with the Gleeble 3800 thermo-mechanical simulator. A general method is described that can be utilized to systematically compare the grain size distributions obtained from the experimental studies. The experimental data has been obtained from laser scanning confocal microscopy images using the mean linear intercept method. A custom-made semi-automatic software has been utilized to process the data rapidly and reliably.