Certified Welder

Primary Function:

The Certified Welder performs aluminum bus and jumper welding in high voltage substation applications, welding rigid tubular bus, connectors, fittings, and flexible jumper terminations in all positions using the GTAW and GMAW processes. This role reads substation plan, section, and bus detail drawings and lays out, cuts, fits, and fabricates bus sections in the field and shop to match the as-built condition. Work is performed to approved welding procedure specifications (WPS) and AWS D1.2 structural aluminum requirements and must pass visual and nondestructive examination prior to energization. The position is based at Dacon's assigned project sites and reports to the Electrical Foreman.

Duties & Responsibilities

Employee may be called upon to perform any or all of the following functions:

Aluminum Bus & Jumper Welding

• Weld aluminum tubular bus, bus connectors, tees, elbows, couplers, expansion fittings, and end caps using GTAW and GMAW in all positions (flat, horizontal, vertical, and overhead).
• Weld jumper terminations, pads, welded connectors, and equipment terminal connections to bus and equipment bushings.
• Prepare joints by cleaning, degreasing, wire brushing with dedicated stainless brushes, and removing oxide immediately prior to welding.
• Control preheat, interpass temperature, travel speed, and heat input to prevent burn-through, distortion, and loss of temper in thin-wall bus.
• Select and set up the correct machine, polarity, filler alloy (e.g., 4043, 5356), shielding gas, and tungsten for the assigned aluminum procedure.
• Store, handle, and control aluminum filler metal and consumables to prevent contamination and moisture pickup.
• Perform aluminum and steel repair welding, modifications, and field corrections as directed.
• Demonstrate the ability to accurately measure and lay out bus and conductor installations, maximizing material utilization, minimizing waste, and ensuring installations are completed efficiently and in accordance with project requirements.

Substation Drawing Interpretation & Bus Fabrication

• Read and work from substation plan, section, elevation, one-line, bus detail, and connection drawings, along with weld symbols and WPS requirements.
• Take field measurements and lay out, cut, bevel, and fabricate bus sections and jumpers to match actual field conditions.
• Fit, align, tack, and square bus runs to specified phase spacing, elevation, slope, and electrical clearance requirements.
• Fabricate and install expansion joints, slip fittings, and hardware to accommodate thermal movement per the drawings.
• Coordinate with the Foreman and lineman crew on bus support locations, insulator placement, and bus setting sequence.
• Identify drawing conflicts and dimensional discrepancies and report them before fabrication proceeds.

Cutting, Grinding & Support Welding

• Perform cutting, sawing, beveling, and grinding of aluminum bus using dedicated aluminum-only tooling and cutting fluids.
• Perform SMAW, FCAW, and GMAW welding on structural steel, base plates, embeds, equipment stands, grating, and supports as qualified.
• Perform oxy-fuel and plasma cutting and gouging on ferrous materials as assigned.
• Support exothermic (cadweld) grounding connections and grounding installation as directed.

Quality & Documentation

• Perform visual inspection of completed welds for porosity, undercut, incomplete fusion, cracking, and profile, and correct defects before turnover.
• Support NDE activities, including visual, dye penetrant, and radiographic examination of bus welds.
• Maintain welder qualification continuity records and comply with the project quality program.
• Document weld locations, procedures used, filler alloy, and repairs on weld maps and daily reports.
• Verify completed bus work against drawings for clearance, spacing, and alignment before energization.

Safety & Hot Work

• Participate in daily job briefings, tailboards, and pre-task safety planning.
• Comply with all Dacon, OSHA, and client-specific safety policies, and use required PPE at all times.
• Identify, correct, and report unsafe conditions, near misses, and incidents immediately to the Foreman or General Foreman.
• Maintain a clean and orderly work area and support site housekeeping and environmental compliance.
• Comply with hot work permit requirements, fire watch procedures, and client-specific hot work controls in the substation yard.
• Verify clearances, tags, and grounding are in place before performing hot work on or near substation equipment and bus.
• Verify ventilation, fume control, and respiratory protection requirements before welding in confined or enclosed spaces.
• Inspect leads, machines, cylinders, regulators, torches, and gas lines before each use and remove defective equipment from service.
• Perform other duties as assigned or requested.

How You Will Make an Impact

• Deliver aluminum bus welds that pass visual and NDE inspection the first time, protecting energization dates that cannot slip.
• Enable the crew to resolve field fit issues on the spot by fabricating bus sections to actual as-built conditions.
• Reduce the risk of hot spots, high-resistance joints, and in-service failures through sound, full-penetration bus connections.
• Protect the substation from fire and damage through strict hot work, clearance, and permit compliance.
• Support quality turnover with complete, accurate weld maps and documentation.

Minimum Qualifications / Experience

Required

• High school diploma or GED, or equivalent field experience; completion of a welding program or apprenticeship preferred.
• Minimum of 3 years of welding experience, including substantial aluminum welding in field construction.
• Demonstrated ability to weld aluminum bus and jumpers in all positions using GTAW and GMAW.
• Current welder qualification/certification to AWS D1.2 (aluminum) for the processes and positions assigned; ability to pass a welder qualification test upon hire and maintain qualification continuity.
• Ability to read and work from substation plan, section, and bus detail drawings, weld symbols, and welding procedure specifications.
• Demonstrated ability to lay out, measure, cut, fit, and fabricate bus sections in the field with minimal supervision.
• Knowledge of aluminum cleaning, joint preparation, filler alloy selection, and distortion and heat input control.
• Proficiency with grinding, cutting, and fit-up tools and equipment.
• OSHA 10 certification (or ability to obtain within 30 days of hire).
• Must be at least 18 years of age and legally authorized to work in the United States.
• Valid driver's license with an acceptable motor vehicle record.
• Ability to pass pre-employment and ongoing drug and alcohol screening, background checks, and client-specific site access requirements.
• Ability to travel to and work at project sites, including overnight travel, extended hours, and callout availability.

Preferred

• Substation construction experience at 15kV and above, including rigid bus and jumper installation.
• AWS D1.1 structural steel and AWS D1.6 stainless qualifications in multiple positions.
• Experience welding bus from 15kV to 765kV voltage classes.
• Rigging, signalperson, and aerial lift qualifications for bus work at height.
• Fitter experience and the ability to develop bus layouts from drawings without direct supervision.
• OSHA 30 certification, First Aid/CPR, confined space entry, and client-specific safety training (e.g., TWIC, Basic Plus).

Physical Requirements:

• Ability to stand, walk, bend, stoop, kneel, squat, crawl, and climb on uneven terrain for the majority of a 10- to 12-hour shift.
• Frequent lifting, carrying, pushing, and pulling of up to 50 pounds unassisted; team lifting of heavier materials as required.
• Ability to work from ladders, scaffolds, elevated platforms, aerial lifts, and in trenches or confined spaces as the task requires.
• Sustained use of hands and arms for tool operation, including repetitive gripping, pinching, and overhead reaching.
• Ability to wear all required PPE for the full shift, including hard hat, safety glasses, gloves, hearing protection, FR clothing, and steel-toe boots.
• Vision, hearing, and depth perception sufficient to identify hazards, hand signals, and moving equipment on an active job site.
• Ability to weld in all positions, including overhead, vertical, kneeling, and in awkward or restricted positions.
• Ability to perform bus welding at height from aerial lifts, ladders, and elevated platforms while wearing fall protection.
• Ability to wear a welding hood, leathers, and respiratory protection for extended periods, including in high heat.
• Sustained fine motor control and steady hand position under a hood.

Environmental Conditions

• Outdoor work in all weather conditions, including extreme heat, cold, rain, wind, and high humidity.
• Exposure to dust, mud, noise, vibration, fumes, and moving heavy equipment.
• Work on active construction, industrial, refinery, and utility sites subject to client-specific safety and access requirements.
• Extended hours, night shifts, weekend work, and emergency or storm callouts may be required.
• Travel to and temporary assignment at project sites away from the home base may be required.
• Exposure to welding fumes, arc flash and UV radiation, sparks, slag, hot surfaces, and compressed gases.
• Hot work in energized substation yards and permitted areas of plants and refineries, subject to strict clearance and fire watch controls.

Reasonable accommodations may be made to enable individuals with disabilities to perform essential functions as defined by Company policy.