Key Responsibilities and Required Skills for Journeyman Sheet Metal Worker

🎯 Role Definition

The Journeyman Sheet Metal Worker is a skilled tradesperson responsible for fabricating, installing, repairing and maintaining sheet metal products and HVAC duct systems in commercial, industrial, and residential projects. This role requires advanced blueprint interpretation, precise layout and pattern development, hands-on metalworking (cutting, bending, forming, welding/brazing), coordination with construction teams and strict adherence to safety and building codes. The ideal candidate demonstrates independent problem solving, quality craftsmanship and the ability to lead by example on the jobsite.

📈 Career Progression

Typical Career Path

Entry Point From:

Sheet Metal Apprentice (completed or near completion)
HVAC Installer / Technician
Metal Fabricator or Mechanical Assembler

Advancement To:

Lead Journeyman / Job Foreman
Sheet Metal Supervisor / Shop Foreman
Project Manager or Estimator (Sheet Metal / HVAC projects)

Lateral Moves:

HVAC Service Technician
CNC Sheet Metal Programmer / Operator
Architectural Sheet Metal Fabricator

Core Responsibilities

Primary Functions

Read, interpret and verify construction blueprints, shop drawings, HVAC schematics and fabrication layouts to develop accurate material lists and cutting patterns for sheet metal ductwork, flashings and custom metal components.
Fabricate ductwork, plenums, fittings and components from galvanized steel, stainless steel, aluminum and copper using hand tools, shears, brakes, rollers and power folding equipment to specified tolerances and code requirements.
Layout and develop complex sheet metal patterns and templates for spiral, rectangular and oval duct systems, architectural panels, roof flashings and specialty metalwork using manual pattern development and computerized nesting/CAD where required.
Install commercial and industrial HVAC duct systems, supply and return plenums, exhaust stacks and rooftop equipment connections including hangers, supports, vibration isolation and anchoring to ensure system integrity and alignment.
Perform MIG, TIG and stick welding as well as brazing and soldering for structural connections, duct seams and specialty fabrications while ensuring weld quality, penetration and appearance per specification.
Operate CNC turret punches, laser cutters, plasma cutters, shear lines and press brakes to produce high-volume and precision components, monitor setup and perform quality adjustments when necessary.
Measure and lay out field cuts, transitions, offsets and complex angles on site, coordinating fit-up and modifications to existing structures while minimizing rework and downtime.
Inspect fabricated components and completed installations for fit, alignment, air leakage, size and compliance with project specifications and SMACNA/ANSI industry standards, performing corrective measures as needed.
Install architectural sheet metal products such as copings, flashings, gutters, downspouts and louvers with meticulous attention to weatherproofing and finish quality.
Seal, caulk and test duct systems for air tightness using duct pressurization and leakage testing methods; document test results and correct deficiencies to meet project performance targets.
Coordinate with general contractors, mechanical/electrical trades and site supervisors to sequence installations, request site access, deliver materials and resolve design or clearance conflicts.
Interpret and apply building codes, local ordinances and safety standards (including SMACNA and HVAC codes) to ensure compliant installations and avoid rework or code violations.
Lead and train apprentices and junior sheet metal workers in safe fabrication techniques, layout methods, tool use and quality standards while promoting on-the-job development and certification completion.
Maintain accurate production records, shop travelers, material nesting reports and time logs to support job costing, invoicing and inventory reconciliation.
Perform preventive maintenance and repairs on rooftop units, exhaust fans, louvers and associated sheet metal components during service calls and planned maintenance visits.
Cut, bend, seam and assemble ductwork using mechanical seaming machines and hand seamers to achieve air-tight connections and maintain structural rigidity for high-pressure systems.
Handle rigging and hoisting of large duct sections and rooftop assemblies, using lifts or cranes in coordination with site safety personnel to ensure safe and damage-free installations.
Select appropriate fasteners, sealants, gasketing and insulation and install thermal and acoustical lining where specified to meet performance and condensation control requirements.
Troubleshoot installation issues, propose practical field modifications and fabricate on-site solutions to fit unusual penetrations, offsets and restricted access areas.
Follow strict site safety protocols including fall protection, confined space entry, lockout/tagout and PPE usage; participate in toolbox talks and safety audits and immediately correct hazards.
Maintain shop and jobsite equipment (brakes, shears, welders, grinders) including routine calibration and minor repairs to ensure consistent production quality.
Manage material staging and inventory control, verify shipments, order specialty metal stock and scrap-material handling while minimizing waste and optimizing yield.
Prepare and review submittals, material takeoffs and as-built documentation; provide accurate feedback to estimators and project managers for change orders and cost adjustments.
Ensure high-quality finishing, touch-up painting, and corrosion protection for exposed sheet metal surfaces to meet architectural and performance requirements.

Secondary Functions

Support project managers and superintendents with field measurements, revision markups and constructability feedback during pre-installation coordination.
Assist estimating team by providing labor hours, fabrication time estimates and value engineering suggestions to improve constructibility and reduce costs.
Participate in continuous improvement initiatives—standardizing shop procedures, improving nesting layouts and suggesting tooling upgrades to increase productivity.
Respond to emergency service calls for HVAC duct repairs, rooftop sheet metal failures and weather-damage remediation in commercial facilities.
Contribute to safety programs by identifying recurring hazards, participating in incident investigations and recommending equipment or process changes.

Required Skills & Competencies

Hard Skills (Technical)

Advanced blueprint and mechanical drawing interpretation (SMACNA standards, HVAC schematics, architectural details).
Sheet metal layout and pattern development for rectangular, round and oval duct systems.
Proficiency with hand and power tools: brakes, shears, rollers, seamers, rivet guns, plasma/laser cutters, grinders and hand seamers.
Welding, brazing and soldering skills (MIG/TIG/Stick) for steel, stainless and copper assemblies; familiarity with weld inspection.
Experience operating CNC equipment, turret punch presses, press brakes and CAD/CAM nesting software (e.g., AutoCAD, ProNest, SolidWorks Sheet Metal).
HVAC duct installation techniques, hangers/supports, vibration isolation and duct sealing methodologies.
Metal fabrication processes including cutting, forming, bending, riveting, clinching and mechanical seaming.
Familiarity with industry codes and standards (SMACNA, ASHRAE, local building codes) and air leakage/testing practices.
Proficient shop math, geometry and measuring techniques for accurate fabrication and field modifications.
Knowledge of insulation types, gasketing, sealants, and methods for thermal and acoustic control in duct systems.
Rigging and material handling skills, including safe use of lifts, cranes and hoisting equipment for rooftop and heavy assemblies.
Preventive maintenance and troubleshooting experience on rooftop sheet metal components and duct-connected equipment.
Experience with quality control processes, measurement instruments and documentation (calipers, tape measures, welding gauges).

Soft Skills

Strong attention to detail and commitment to producing high-quality craftsmanship on every job.
Effective verbal communication to coordinate with foremen, trades and customers and explain technical issues clearly.
Problem-solving mindset—able to create practical field solutions for site challenges while maintaining safety and quality.
Time management and organizational skills to meet project deadlines and manage multiple tasks on fast-paced sites.
Leadership and mentoring ability to train apprentices, lead small crews and promote best practices.
Adaptability to changing site conditions, re-sequencing work and handling last-minute design revisions.
Customer-service orientation when interacting with building owners, facility managers and inspectors.
Safety-first attitude with consistent adherence to PPE, fall protection, and jobsite safety protocols.

Education & Experience

Educational Background

Minimum Education:

High School Diploma or GED

Preferred Education:

Completion of a recognized sheet metal apprenticeship program or technical school diploma in sheet metal technology or HVAC
Journeyman certification, state license or contractor qualification where applicable

Relevant Fields of Study:

Sheet Metal Technology
HVAC/R Technology
Mechanical Trades / Industrial Fabrication
Welding Technology

Experience Requirements

Typical Experience Range:

4 to 8 years of hands-on sheet metal fabrication and installation experience, including completion of a formal apprenticeship or equivalent on-the-job training

Preferred:

5+ years as a journeyman sheet metal worker with documented experience on commercial and industrial projects, experience with CNC and CAD tools, and certifications for welding or specialized equipment (e.g., confined space, rigging, OSHA 10/30).
Proven track record of leading crews, performing field layout, and meeting SMACNA/ASHRAE quality and performance standards.