Key Responsibilities and Required Skills for Aluminum Structural Helper

🎯 Role Definition

The Aluminum Structural Helper assists experienced fabricators, assemblers and finishers in the production of aluminum structural components and assemblies. Primary duties include material handling, layout and marking, deburring, drilling, riveting, sealing and surface preparation. This role supports quality control, maintains a safe and organized work environment, and follows blueprints and work orders to help deliver precision aluminum parts for commercial, marine, aerospace or industrial projects. Ideal candidates are safety-minded, physically capable, able to read basic drawings, and willing to learn fabrication techniques such as riveting, fastening, and light welding preparation.

📈 Career Progression

Typical Career Path

Entry Point From:

General Laborer in manufacturing or construction
Warehouse or material handler with metal experience
Entry-level sheet metal or assembly apprentice

Advancement To:

Aluminum Fabricator / Structural Assembler
Skilled Sheet Metal Technician
Lead Fabricator or Production Supervisor

Lateral Moves:

Finish Technician (polishing/paint prep)
Maintenance Assistant / Tool Room Technician

Core Responsibilities

Primary Functions

Assist senior fabricators with measuring, marking, and cutting aluminum plate, extrusions and sheet to specified tolerances using tapes, calipers and layout tools; ensure accurate material preparation for structural assemblies.
Set up and operate hand and basic power tools such as drills, grinders, pneumatic rivet guns, torque wrenches and deburring tools to fasten and finish aluminum components following work orders and blueprints.
Perform hole drilling, countersinking and chamfering on aluminum parts using drill presses, portable drills and drill jigs, ensuring hole alignment and dimensional accuracy for riveted or bolted assemblies.
Install mechanical fasteners including blind rivets, solid rivets, bolts and self-tapping screws; torque fasteners to specification and record torque values when required for quality documentation.
Assist with layout and tack-assembly of structural frames, bulkheads, brackets and supports, holding components in fixtures and under clamps as instructed to maintain alignment during assembly.
Prepare aluminum surfaces for bonding, sealing or welding by cleaning, sanding, sanding-blending and degreasing to remove oxidation and contaminants that could affect adhesion or aesthetic finish.
Support rivet and structural assembly processes by positioning parts, operating rivet guns, installing rivet backup tools, and inspecting completed rivet lines for proper set and spacing.
Load, unload and stage raw material, subassemblies and finished structural components using hoists, slings and pallet jacks while complying with safe lifting and rigging practices.
Assist with basic weld preparation such as fit-up, tack-welding support, edge preparation and grinding of joints for hand-off to certified welders when applicable.
Perform routine finishing tasks including grinding, sanding, deburring, edge dressing and surface polishing to meet specified aesthetic and dimensional standards for aluminum structural parts.
Read and interpret basic blueprints, assembly drawings and written fabrication instructions; flag discrepancies and ask questions to prevent rework and maintain assembly quality.
Perform first-article inspections and basic dimensional checks with calipers, micrometers and gauges under the direction of quality control personnel to verify parts meet tolerances.
Maintain accurate documentation of completed tasks, material lot numbers, fastener usage and inspection results to support traceability and QA requirements in regulated environments.
Support jig and fixture setup by cleaning mating surfaces, aligning tooling components and assisting with fastener installation to ensure repeatable assembly accuracy.
Operate basic shop equipment such as band saws, shear machines and deburring stations under supervision, following lockout/tagout (LOTO) and machine safety protocols.
Assist in layout and trim operations using templates and patterns for cut-to-fit pieces in structural assemblies, making fine adjustments as directed by senior fabricators or supervisors.
Apply sealants, primers or corrosion-inhibiting compounds to prepared aluminum areas using brushes, rollers or caulking guns according to product data sheets and specified cure times.
Execute assigned work in compliance with company safety policies and OSHA standards, wear required PPE, and participate in daily safety briefings and toolbox talks to maintain a zero-incident mindset.
Clean, maintain and perform basic preventive maintenance on hand tools, jigs and fixtures; report worn or damaged equipment to the supervisor to prevent production delays.
Support production flow by staging kits, collecting consumables, replenishing fasteners and coordinating with inventory or purchasing to minimize downtime on assembly lines.
Participate in continuous improvement activities by suggesting process improvements, documenting recurring issues, and assisting with implementation of standardized work and 5S practices.
Assist quality and production teams with non-conformance investigations by collecting samples, documenting findings and supporting rework or containment actions as required.
Provide cross-functional support during peak demand cycles by assisting with packing, crating and preparing finished aluminum assemblies for shipment while ensuring protection against scratching and distortion.
Attend on-the-job training and certification sessions to develop skills in advanced riveting, welding prep, blueprint reading and aluminum-specific handling techniques.

Secondary Functions

Maintain a clean, organized and safe work area in accordance with 5S and company housekeeping standards.
Track and report tool and consumable usage to supervisors to support inventory control and cost tracking.
Assist with basic inventory tasks such as counting fasteners, labeling materials and rotating stock to minimize waste and maintain production readiness.
Help load and secure components for internal or customer shipments, following packing lists and protective packaging requirements for aluminum parts.
Support preventative maintenance checks on assembly fixtures and basic shop equipment and report any safety hazards or malfunctioning machines.
Participate in cross-training to expand capabilities across assembly, finishing and material handling functions.
Document daily production activities and communicate progress or issues to the lead to maintain production schedules.
Follow all environmental and hazardous-material handling procedures when working with solvents, primers and sealants.
Assist engineering and quality teams during prototype runs by providing hands-on support to test fit-ups and initial assembly sequences.
Share observations on potential process improvements and assist in small pilot projects to increase assembly efficiency and reduce scrap.

Required Skills & Competencies

Hard Skills (Technical)

Blueprint and technical drawing interpretation for basic layout, hole patterns and assembly orientation.
Proficient use of hand tools and power tools common to aluminum fabrication (drills, rivet guns, grinders, rotary sanders).
Experience with pneumatic rivet guns, hand riveters and knowledge of rivet installation techniques.
Basic measuring skills with tape measures, calipers, micrometers and depth gauges to verify part dimensions.
Familiarity with drilling, countersinking, reaming and chamfering techniques for aluminum.
Understanding of torque specifications and use of torque wrenches for fastener installation.
Surface preparation skills including sanding, degreasing, deburring and anodize touch-up procedures.
Knowledge of safe material handling, rigging basics and forklift or pallet jack operation (certification a plus).
Basic familiarity with adhesive bonding and sealant application for structural joints.
Experience operating shop equipment such as band saws, drill presses and deburring stations.
Basic quality inspection skills and recordkeeping for traceability and non-conformance reporting.
Familiarity with LOTO procedures and general machine safety practices.
Basic welding preparation skills (fit-up, tack-weld support and weld joint cleanup) preferred in some environments.
Competence with kit building and material staging to support efficient assembly workflows.

Soft Skills

Strong attention to detail to ensure parts meet tolerances and surface finish requirements.
Good verbal communication for coordinating with leads, fabricators and quality teams.
Team-oriented attitude with the ability to follow instructions and support experienced craftsmen.
Dependable punctuality and ability to manage time in a fast-paced production environment.
Physical stamina and dexterity for repetitive tasks, lifting and working in confined spaces.
Problem-solving mindset to identify and escalate process or quality issues proactively.
Adaptability to learn new tools, fixtures and fabrication techniques quickly.
Safety-first mentality, consistently using PPE and following established procedures.
Willingness to accept feedback and improve workmanship through hands-on coaching.
Organizational skills to maintain clean workstations and accurate job documentation.

Education & Experience

Educational Background

Minimum Education:

High school diploma or GED required.

Preferred Education:

Trade school certificate or vocational training in welding, sheet metal, or metal fabrication.
Certifications in forklift operation, OSHA 10-hour safety, or basic welding (MIG/TIG) are advantageous.

Relevant Fields of Study:

Welding Technology
Mechanical or Industrial Technology
Metal Fabrication / Sheet Metal Technology
Manufacturing Technology
Industrial Maintenance

Experience Requirements

Typical Experience Range:

0 to 3 years in manufacturing, metal fabrication, or construction support roles; entry-level candidates with relevant hands-on training are welcome.

Preferred:

1–3 years of direct experience in aluminum fabrication, structural assembly, rivet work or sheet metal environments; prior exposure to aerospace, marine or commercial structural components is a plus.