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We were commissioned to manufacture a flanged and butt-welded firebox for a historic boiler at the Barracks Steam Museum in Aberdeen. The project required precision engineering to replicate the original firebox dimensions while ensuring compliance with modern boiler safety standards.
The process began with careful measurement of the original firebox to determine accurate dimensions and plate sizes. Once the new boiler plate was procured, our workshop team pressed two new firebox endplates and hot-formed the wrapper plate over a curved former to match the original shape and curvature
The endplates and wrapper were prepared for welding by grinding bevels onto all joining edges, ensuring optimal penetration and a high-quality fusion. The assembly process included:
- Tack welding the firebox components together for initial alignment.
- Inspection and approval by the insurance surveyor before full welding.
- Full fusion welding by our coded welders to secure structural integrity.
In this project, the foundation ring and firedoor ring were retained and seal-welded to the new box. Additionally, new roof girders were manufactured, and stay bars were machined and installed to ensure the firebox met both structural and operational standards.
The completed firebox was a precise reproduction of the original, fully integrated with the retained components, and ready for safe operation. This project demonstrated our expertise in heritage boiler restoration, precision welding, and custom fabrication, balancing historical accuracy with modern safety compliance.
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