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Key Responsibilities and Required Skills for Boilermaker

💰 $50,000 - $95,000

ManufacturingConstructionIndustrialSkilled Trade

🎯 Role Definition

A Boilermaker fabricates, assembles, installs, inspects and maintains boilers, pressure vessels, tanks, and large steel structures used in industrial settings such as power plants, shipyards, and refineries. This role combines advanced welding and metalworking skills with rigging, layout, inspection and adherence to codes and safety standards (ASME, API, AWS, OSHA). The ideal candidate reads blueprints and welding symbols, performs complex field and shop installations, executes hydrostatic and pneumatic testing, and collaborates with engineers and trades to deliver safe, compliant, and high-quality pressure-containing systems.

📈 Career Progression

Typical Career Path

Entry Point From:

  • Entry-level Welder / Welding Apprentice
  • Pipefitter or Structural Fabricator
  • Industrial Maintenance Technician

Advancement To:

  • Journeyman Boilermaker
  • Lead Boilermaker / Foreman
  • Welding Inspector (CWI) / Quality Control Specialist
  • Project Superintendent or Fabrication Manager

Lateral Moves:

  • Pressure Vessel Welder
  • Rigging and Lifting Specialist
  • Maintenance Millwright

Core Responsibilities

Primary Functions

  • Fabricate, assemble and erect boilers, pressure vessels, large tanks and heavy steel structures according to engineering blueprints, detailed fabrication drawings and welding procedure specifications (WPS), ensuring dimensional accuracy and structural integrity.
  • Perform high-quality welding using multiple processes (SMAW, GTAW/TIG, GMAW/MIG, FCAW) on ferrous and non-ferrous metals, following AWS, ASME (Section I, VIII) and client-specific welding codes and procedure qualifications.
  • Read, interpret and mark up fabrication prints, isometric piping drawings and welding symbols to lay out parts, cut plate and structural members, and confirm fit-up prior to welding.
  • Execute field installations and rigging of heavy boiler sections, pressure vessels and heat exchangers using cranes, hoists, slings and taglines while coordinating lifts with riggers and site supervisors to ensure safe placement and alignment.
  • Set up and operate oxy-fuel cutting, plasma cutting and other thermal cutting equipment to prepare weld edges and contours with precise tolerances required for fit-up and weld preparation.
  • Perform mechanical assembly tasks including bolt-up, flange make-up, alignment checks and installation of supports, saddles, and anchoring systems to secure pressure equipment and structures.
  • Conduct non-destructive testing (NDT) support activities such as visual inspection, assist or coordinate radiographic (RT), ultrasonic (UT), magnetic particle (MT), and dye penetrant (PT) inspections, and document results for quality records.
  • Carry out hydrostatic, pneumatic and leak tests on assembled pressure systems, record pressures, monitor for leaks, and perform repairs or rework to ensure vessels meet functional and safety specifications.
  • Prepare and maintain weld logs, material traceability records, and inspection reports; ensure all welding, heat treatment and NDE documentation is complete and compliant with regulatory and client requirements.
  • Perform pre-weld fit-up, tack welding and dimensional checks, adjust and shim components as necessary to meet flatness, parallelism and concentricity tolerances, and verify alignment before final welding.
  • Apply appropriate heat treatment and post-weld procedures such as stress relieving or preheating in accordance with WPS and metallurgical requirements to prevent cracking and ensure long-term component reliability.
  • Operate and maintain shop and portable welding, cutting and fabrication tools, including grinders, saws, hydraulic torque wrenches and plate rollers, ensuring equipment is in safe working order and calibrated as required.
  • Remove and replace damaged or corroded boiler and vessel components during maintenance outages, perform on-site repairs under time constraints, and coordinate with maintenance planners to minimize downtime.
  • Install insulation, lagging and protective coatings on boilers, piping and vessels as part of final assembly and handover, ensuring thermal performance and corrosion protection meet specifications.
  • Collaborate with engineers, QC inspectors and project managers to identify and implement corrective actions for fabrication and field deficiencies, participate in root-cause analysis and continuous improvement activities.
  • Adhere to confined space, lockout/tagout (LOTO), fall protection and respiratory protection procedures when working in restricted or hazardous environments; obtain required permits and coordinate safety watch when applicable.
  • Train and mentor apprentices and junior welders on proper welding techniques, blueprint interpretation, rigging practices, safety protocols and code compliance to raise overall team competency and productivity.
  • Schedule work activities, estimate material and labor needs, and support foremen in sequencing tasks for efficient workflow in both shop and field environments.
  • Perform final visual and dimensional inspections, apply identification stamps or serial numbers per project standards, and prepare completed assemblies for shipping or site installation.
  • Maintain a proactive safety culture by identifying hazards, reporting near misses, participating in toolbox talks and safety audits, and implementing corrective measures to reduce incidents.
  • Ensure compliance with environmental, health and safety regulations, including proper handling and disposal of welding fumes, solvents and waste materials as required by OSHA and company policies.
  • Provide accurate feedback on material substitutions, fabrication challenges and constructability issues during pre-fabrication reviews and project meetings to inform scope and schedule adjustments.

Secondary Functions

  • Support pre-job planning and material staging by assisting in inventory checks, cut lists and parts marking to expedite fabrication cycles.
  • Contribute to continuous improvement initiatives by suggesting process improvements, tooling upgrades and workflow optimizations that increase quality and reduce rework.
  • Assist quality control teams during audits by preparing traceability documentation, weld procedure records and maintenance logs for client review.
  • Participate in cross-functional safety and scheduling meetings, offering field perspective on practical constraints and mitigation strategies.
  • Aid in emergency shutdowns and rapid-response repair efforts by providing on-call support to restore critical systems with minimal operational interruption.
  • Help maintain shop cleanliness and tool organization, ensuring a safe, efficient and professional workspace for all fabrication activities.

Required Skills & Competencies

Hard Skills (Technical)

  • Proficient in welding processes: SMAW (stick), GTAW/TIG, GMAW/MIG and FCAW — demonstrated ability to produce high-quality welds on carbon steel, stainless steel and alloy steels.
  • Certified welding qualifications and experience working to AWS and ASME codes (e.g., WPS/PQR compliance; ASME Section I/II/V/VIII familiarity).
  • Blueprint reading and interpretation of fabrication drawings, isometrics, welding symbols and geometric tolerances.
  • Heavy rigging and lifting competency: slinging, crane signals, load balancing, and use of hoists and spreader bars for safe placement of large assemblies.
  • Proficient in thermal cutting methods: oxy-fuel cutting, plasma cutting, and mechanized cutting equipment.
  • Experience with hydrostatic and pneumatic testing procedures, leak detection and pressure test documentation.
  • Knowledge of non-destructive examination (NDE) processes and ability to support RT/UT/MT/PT inspections and interpret results.
  • Skilled in precision measuring tools: calipers, micrometers, levels, squares, plumb lines and laser alignment tools.
  • Proficient in pipe fitting, flanging, bolt-up procedures and torqueing to specified values; experience with gaskets and sealants for pressure systems.
  • Familiarity with heat treatment, preheat/postheat techniques and metallurgical considerations to prevent cracking and distortion.
  • Competence with hand and power fabrication tools: grinders, saws, hydraulic presses, rollers and welding manipulators.
  • Experience maintaining weld logs, quality documentation, material traceability and completing inspection checklists.
  • Forklift and telehandler operation for material handling (if applicable).
  • Confined space entry and permit experience; knowledge of LOTO procedures and atmospheric monitoring equipment.
  • Basic understanding of corrosion protection, insulation application and coatings used on boilers and pressure vessels.

Soft Skills

  • Strong attention to detail and commitment to producing code-compliant, high-integrity welds and assemblies.
  • Excellent problem-solving and troubleshooting ability under time-sensitive outage and field repair conditions.
  • Clear communication skills to coordinate with supervisors, riggers, inspectors and project engineers in dynamic environments.
  • Team-oriented with the ability to mentor apprentices and collaborate across trades to meet project milestones.
  • High safety orientation and ability to model and enforce safe behaviors on-site.
  • Time management, reliability and the capacity to prioritize tasks to meet deadlines and minimize production downtime.
  • Adaptability to changing work locations (shop, plant floor, field) and variable environmental conditions.
  • Physical stamina, dexterity and balance to work at heights, in awkward positions and for extended periods.
  • Professionalism when interacting with clients and inspection personnel during site visits and audits.
  • Continuous learning mindset and willingness to maintain and upgrade certifications and technical skills.

Education & Experience

Educational Background

Minimum Education:

  • High school diploma or equivalent (GED) with vocational training in welding or metal fabrication.

Preferred Education:

  • Trade school diploma or technical certificate in Welding Technology, Boilermaking, or Metal Fabrication.
  • Additional certifications such as AWS welding credentials, CWI (Certified Welding Inspector) or OSHA safety certifications.

Relevant Fields of Study:

  • Welding Technology
  • Mechanical or Industrial Trades
  • Metal Fabrication / Structural Fabrication
  • Pipefitting / Mechanical Maintenance

Experience Requirements

Typical Experience Range: 2–8 years of progressive experience in boilermaking, heavy fabrication, or pressure equipment installation.

Preferred: 4+ years of boilermaker-specific experience with documented welding qualifications, experience with ASME code work, and prior exposure to field installations and hydrostatic testing.

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