Little Gecko® welding carriages · Engineering, QC & worldwide export from Beijing, China
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Boiler Welding — Tube Bundles, Drums & Shells

A boiler is a tubesheet problem multiplied by hundreds, wrapped around a shell problem. We build the machine for the multiplication — and the carriages for the shell.

Boiler Welding

The same weld × 200, executed identically

Boiler fabrication stacks two welding problems: hundreds of tube-to-tubesheet joints that must each be leak-tight, and long drum and shell seams in thick plate. Done by hand, joint 180 never looks like joint 1. Done by machine, every joint gets the same parameter set — and the drum seams get the same discipline.

  • Tube-to-tubesheet joints on boilers, condensers and coolers — tube inner diameter Ø25–108 mm
  • Double half-circle and full-circle working modes for horizontal and vertical tubes
  • PLC touch-screen control with servo rotation — 16.7 s per joint maximum
  • Drum, shell and membrane wall seams handled by the carriage family
What we recommend: HLGB25-108 automatic tube-to-tubesheet machine with the expanding head made to order for your tube gauge — plus ZG straight-track and RG flexible-track carriages for drum and shell seams with the same parameter discipline.
The difference: The head centres itself in the bore, the machine welds, the operator moves to the next hole. Production counting on the PLC screen tells you exactly what each shift produced — no more estimating from gas bottles.
See the HLGB25-108
HLGB tube-to-tubesheet welding head working on a tubesheet — real photo Tube-to-tubesheet automatic welding machine HLGB25-108
Seam Types We Cover

Which Carriage Welds What in Boilers

Typical joint / seamRecommended machine
Tube-to-tubesheet joints, Ø25–108 mmHLGB25-108 tube-to-tubesheet machine
Drum & shell longitudinal seamsZG-III-Q1 straight-track carriage
Shell circumferential seamsCX-III-Q1 magnetic crawler
Membrane wall & panel filletsJJ fillet carriage
Watch It Work

Automatic Tube-to-Tubesheet Welding — Real Footage

HLGB25-108 welding a tube-to-tubesheet joint
FAQ

Boilers Welding — Common Questions

We have many different tube gauges in one boiler — one head or several?
The pneumatic expanding head clamps within a 3 mm tube-diameter band, so heads are made to order per gauge. Shops that run mixed bundles usually keep two or three heads and swap them in minutes — the main unit and cabinet are unchanged.
Can it weld both horizontal and vertical tubesheet layouts?
Yes — the PLC offers two working modes: full-circle for vertically arranged tubes (the spindle rotates 360° plus overlap) and double half-circle for horizontal tubes (two 180° passes so the torch never works the awkward sector). Switching is one touch on the screen.
Do we need to buy a new welding power source?
No. The machine uses your existing MIG / MAG / FCAW power source and includes its own integrated wire feeder and dedicated 350 A torch. Current and voltage are adjustable right on the control cabinet panel, synchronised with your power source.

Fabricating Boiler Tube Bundles?

Tell us tube inner diameter, wall thickness and material — we will configure the expanding head and quote within 24 hours.

Get a Quote