Furnace guy said boiler needs replaced because the top is rusty. Why can’t plates be welded to it to seal it up --74.138.xxx.xxx

I'm sure sheet metal could be attached in some manner to cover the rust. However once you modify it then it would no longer be covered by any manufacturer's warranty as well as voiding any UL listing. I doubt that it would be cost effective to do it. IMO the reward vs risk isn't worth it. --96.237.xx.xx

Really -- weld plates over rusted boiler????? Are you serious? --99.103.xxx.xxx

The top, as in the cover? --50.107.xxx.xxx

NE he said to "seal it up". if cover -- wire brush it and rustolium... --99.103.xxx.xxx

Chances are you are only looking at the skin that covers the insulation, once this is removed you will see the body of the water vessel where all the safety controls screw into the various ports and the hot water or steam comes out from the largest pipe. Welding the vessel is a job only a certified person should do, it is usually less expensive to replace a faulty interior plate that has cracked - it has to come off to be welded anyway. --76.188.xxx.xx

It’s the shell not internal but if it could be done for $6k I would just replace. I’m waiting on an estimate after a total of 9 we’re called and only 2 called back and then only one showed up. --74.138.xxx.xxx

Sounds like a disaster in the making....film at 11. --174.225.xxx.xx

If there is surface rust then use a wire brush to remove rust. If the rust is deeper then replace the boiler. For cast iron sectional boilers then can go into the Slant fin website. Boilers eventually fail. If there is a leak in the heating system then fresh make up water is drawn in where fresh water has oxygen which promotes rust. A boiler system should be water tight where the oxygen is used up. --147.194.xxx.xx

So the cover you take off for service is rusty and you need a new boiler? Sounds like someone is looking to have a nice Christmas on your dime. --174.201.x.xxx

Fix it right the first time and avoid future problems. --47.156.xx.xx

Just got the estimate $37,000 --74.138.xxx.xxx

Get another one. How big of a boiler? --50.107.xxx.xxx

I don't know what kind of building you have but a $37,000 boiler would heat a high school. --50.107.xxx.xxx

That's funny!! NE.. He still hasn't answered if its the service panel or what he has.. All my forced hot water boilers are rusty.. --71.232.xxx.xxx

Find a high school that has vocational classes, this would make a good project for someone learning auto body work, they would reskin in about 3 classroom sessions - use screws not welding. --76.188.xxx.xx

Instead of installing a larger boiler it is better to install multiple boilers then stage the boilers so only one boiler will be required at a time to meet the heat demand. Much less natural gas or heating oil is used for multiple boilers. If one boiler fails then can fix where the other boilers will continue to heat. Suppose one million Btu is required where five 200,000 Btu boilers will make one million Btu. With a electronic control like a Tekmar the boilers will fire according to load where it is very rare all the boilers will fire at one time except on coldest day or night. With unions on each boiler then if one boiler fails it is easy to swap out a faulty boiler. Visit the Slant fin website then check out commercial boilers with the multiple option. There are special manifolds where the boilers can be connected up. With multiple the boilers will operate less time as the boilers rotate along with life expectancy will be longer. The nameplate on the boiler will have the Btu input then go from there how to divide up. Check out videos on You Tube about boilers. Generally a conventional gas boiler around 200,000 to 300,000 Btu will cost around $3,500 to $4,000 dollars each boiler. If money is going to spent then over the money has to improve efficiency by reducing operating costs. --147.194.xxx.xx

air or water --73.182.xxx.xxx

Since you don’t boil air I thought it was self explanatory but it’s a water boiler ng. --174.231.xxx.xxx

--73.182.xxx.xxx