Boilermakers

• Nature of the Work

  Boilermakers and boilermaker mechanics make, install, and repair boilers, vats, and other large vessels that hold liquids and gases. Boilers supply steam to drive huge turbines in electric power plants and to provide heat or power in buildings, factories, and ships. Tanks and vats are used to process and store chemicals, oil, beer, and hundreds of other products.

  Boilers and other high pressure vessels are usually made in sections by casting each piece out of molten iron or steel. Manufacturers are increasingly automating this process to increase quality. The boiler sections are then welded together, often using automated orbital welding machines, which make more consistent welds than possible by hand. Small boilers may be assembled in the manufacturing plant; larger boilers are usually assembled on site.

  Following blueprints, boilermakers locate and mark reference points on the boiler foundation for installing boilers and other vessels, using straightedges, squares, transits, and tape measures. They attach rigging and signal crane operators to lift heavy frame and plate sections and other parts into place. They align sections, using plumb bobs, levels, wedges, and turnbuckles; use hammers, files, grinders, and cutting torches to remove irregular edges so they fit properly; and bolt or weld them together. Boilermakers align and attach water tubes, stacks, valves, gauges, and other parts and test complete vessels for leaks or other defects. Usually they assemble large vessels temporarily in a fabrication shop to insure a proper fit and again on their permanent site.

  Because boilers last for a long time—35 years or longer—boilermakers regularly maintain them and update components such as burners and boiler tubes to make them as efficient as possible. Boilermaker mechanics maintain and repair boilers and similar vessels. They clean or direct others to clean boilers and inspect tubes, fittings, valves, controls, and auxiliary machinery. They repair or replace defective parts, using hand and power tools, gas torches, and welding equipment, and may operate metalworking machinery to repair or make parts. They also dismantle leaky boilers, patch weak spots with metal stock, replace defective sections, or strengthen joints.

• Working Conditions

  Boilermakers often use potentially dangerous equipment such as acetylene torches and power grinders, handle heavy parts, and work on ladders or on top of large vessels. Work may be done in cramped quarters inside boilers, vats, or tanks that often are damp and poorly ventilated. To reduce the chance of injuries, they may wear hardhats, harnesses, respirators, protective clothing, and safety glasses and shoes. Boilermakers usually work a 40-hour week but may experience extended periods of overtime when equipment is shut down for maintenance. Overtime work may also be required to meet construction or production deadlines.

• Employment

  Boilermakers held about 20,000 jobs in 1994. About 44 percent worked in manufacturing, primarily in boiler manufacturing shops, iron and steel plants, petroleum refineries, chemical plants, and shipyards. One-third worked in the construction industry, assembling and erecting boilers and other vessels. Some also work for boiler repair firms, railroads, and in Navy shipyards and Federal power facilities.

• Training, Other Qualifications, and Advancement

  Most training authorities recommend a formal apprenticeship to learn this trade. Some people become boilermakers by working as helpers to experienced boilermakers, but generally lack the wide range of skills acquired through apprenticeship. Apprenticeship programs usually consist of 4 years of on-the-job training, supplemented by about 144 hours of classroom instruction each year in subjects such as set-up and assembly rigging, welding of all types, blueprint reading, and layout. Experienced boilermakers often attend apprenticeship classes to keep their knowledge current.

  When an apprenticeship becomes available, the local union will publicize the opportunity by notifying local vocational schools and high school vocational programs. Qualified applicants take an aptitude test administered by the union specifically designed for boilermaking. The apprenticeship is awarded to the person scoring highest on this test.

  When hiring helpers, employers prefer high school or vocational school graduates. Courses in shop, mathematics, blueprint reading, welding, and machine metalworking are useful. Mechanical aptitude and the manual dexterity needed to handle tools also are important.

  Some boilermakers advance to supervisory positions; because of their broader training, apprentices generally have an advantage in promotion.

• Job Outlook

  Persons who wish to become boilermakers may face some competition, due to the limited number of apprenticeships available and the relatively good wages a journey boilermaker earns. In addition, employment of boilermakers is expected to decline through the year 2005. However, a limited number of openings will arise from the need to replace experienced workers who leave the occupation.

  Growth should be limited by several factors: The trend toward repairing and retrofitting rather than replacing existing boilers; the use of smaller boilers, which require less on-site assembly; automation of production technologies; and an increase in the use of imported boilers.

  Most of the industries that purchase boilers are sensitive to economic conditions. Therefore, during economic downturns, construction boilermakers may be laid off. However, because boilers are maintained and repaired even during economic downturns, boilermaker mechanics generally have more stable employment.

• Earnings

  According to the limited data available, boilermakers who usually worked full time had median earnings of about $532 per week in 1994.

  According to the International Brotherhood of Boilermakers, journey boilermakers earned $21.20 per hour in 1994. Apprentices started at 60 percent of journey wages, or about $12.70 hourly, with wages increasing gradually to the journey wage as progress is made in the apprenticeship. However, wages vary greatly around the country, with higher wages in Northeastern, Great Lakes, and Far Western cities than in other areas of the country.

  Most boilermakers belong to labor unions. The principal union is the International Brotherhood of Boilermakers. Others are members of the International Association of Machinists, the United Automobile Workers, and the United Steelworkers of America.

• Related Occupations

  Workers in a number of other occupations assemble, install, or repair metal equipment or machines. These include assemblers, blacksmiths, instrument makers, ironworkers, machinists, millwrights, patternmakers, plumbers, sheetmetal workers, tool and die makers, and welders.

• Sources of Additional Information

  For further information regarding boilermaking apprenticeships or other training opportunities, contact local offices of the unions previously mentioned, local construction companies and boiler manufacturers, or the local office of the State employment service.

  For general information regarding boilermaking and opportunities in the boiler manufacturing industry, contact:
  American Boiler Manufacturing Association, 950 North Glebe Rd., Suite 160, Arlington, VA 22203-1824.

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