Onboarding plan
Refractory Repairer Onboarding Plan (30-60-90 Days)
A practical, printable plan to take a new refractory repairer from first day to full productivity.
Refractory Repairer onboarding at a glance
Week one covers orientation, safety and shadowing. Days 1–30 build vocabulary and supervised practice on core procedures; days 31–60 move to independent work with competency sign-offs; days 61–90 focus on full productivity, cross-training and a credential plan.
Before day one
- Confirm start date, schedule, pay and supervisor in writing
- Verify required credentials: Confined space training, Respirator fit testing (as applicable)
- Prepare equipment and access: jackhammers; mixers; gunning machines; masonry saws
- Assign a buddy or preceptor
- Enroll the new hire in Refractory Repairer training so foundations are covered before or during week one
Week one: orient and protect
- Workplace tour, emergency procedures and incident reporting
- Follow confined space rules
- Wear respirators for silica
- Use heat protection
- Lock out equipment
- Shadow an experienced refractory repairer through a full shift
- Training modules 1–3: role foundations, a day on the job and essential vocabulary (15 terms)
Days 1–30: learn
Goal: perform core tasks safely under supervision.
- Supervised practice: install castable refractory
- Supervised practice: enter a confined space safely
- Supervised practice: follow a refractory dry-out schedule
- Training modules 4–7: duties, step-by-step tasks, tools and safety
- 30-day check-in: confidence, questions and early wins
Days 31–60: contribute
Goal: handle a regular workload independently.
- Inspect refractory linings: independently
- Tear out worn material: independently
- Install brick and castable: independently
- Spray or gun refractory: independently
- Competency sign-offs completed (see checklist below)
- Training final knowledge check and certificate of completion
- 60-day check-in
Days 61–90: own
Goal: full productivity and a growth plan.
- Meet productivity and quality targets for the role
- Begin cross-training on a secondary task
- Agree on a credential goal (for example, Confined space training)
- Discuss the career path: Helper → Refractory Repairer → Lead Installer
- 90-day review
Competency checklist
| Skill or task | Trained | Observed | Signed off |
|---|---|---|---|
| Install Castable Refractory | |||
| Enter a Confined Space Safely | |||
| Follow a Refractory Dry-Out Schedule | |||
| Refractory installation | |||
| Mixing castables | |||
| Gunning | |||
| Demolition |
How to measure onboarding success
- Time to independent work orders
- Comeback, rework or scrap rate
- Billable or productive hours versus target
- 90-day retention
How Refractory Repairer training maps to this plan
- Introduction to the Refractory Repairer Role
- A Day on the Job
- Essential Refractory Repairer Vocabulary
- Core Duties and Responsibilities
- Common Tasks, Step by Step
- Tools, Equipment and Technology
- Safety, Compliance and Professional Standards
- Skills Employers Look For
- Launching Your Refractory Repairer Career
- Final Knowledge Check