Senior Finite Element Analysis; FEA) Engineer – Utility Structures

Race Rock is looking for a Senior Finite Element Analysis Engineer to become the go-to analysis expert on our Engineered Structures team. In this high-visibility role, you’ll lead finite element analysis for the power delivery and highway steel structures; from complete pole and overhead structures to the specific bolted and welded assemblies that hold them together. Reporting directly to the VP of Engineering, you will own the FEA function from first model to final stress report, and you will set the analysis methods and standards our growing in-house team will build on.

If you are an experienced analyst who wants your work to shape both critical infrastructure and the future of an engineering department, we would like to talk with you.

• Perform linear and nonlinear static structural analyses of utility steel poles, arms, base plates, and connections to evaluate stress, deflection, buckling, and overall structural integrity.
• Develop detailed FEA models of gusset plate connections and evaluate critical limit states, including yielding, block shear, local buckling, bearing, and fracture.
• Analyze and size welded connections (fillet, CJP, and PJP groove welds), including weld stress evaluation, fatigue assessment, and compliance with AWS D1.1 and AISC 360.
• Build, mesh, and validate models using ANSYS Mechanical, Abaqus, FEMAP/NX Nastran, or equivalent tools, applying appropriate boundary conditions, load cases, contact, and mesh convergence studies.
• Perform mechanical analyses as required, including fatigue, modal, buckling, and thermal-structural evaluations.
• Validate FEA results through hand calculations, closed-form solutions, and code checks per ASCE 48, ASCE 10, and NESC requirements.
• Prepare clear, well-documented stress reports and calculation packages for customer review, design verification, and engineering sign-off.
• Support design, drafting, and manufacturing teams with design optimization.
• Create, import, repair, idealize models for FEA pre-processing by utilizing 3D CAD software such as Solid Work, Inventor, Creo.
• Develop and maintain FEA modeling guidelines, analysis procedures, and best practices for the engineering department.
• Mentor junior engineers and perform peer reviews of models, calculations, and reports.

• Bachelor of Science in Mechanical, Civil/Structural, or Aerospace Engineering from an ABET-accredited program.
• 10+ years of experience performing structural FEA and stress analysis, with a strong focus on static and mechanical analysis of steel structures.
• Demonstrated expertise in the analysis and design of gusset plates and welded connections.
• Advanced proficiency with at least one major FEA package (ANSYS, Abaqus, FEMAP/NX Nastran, or equivalent).
• Strong working knowledge of AISC, AWS D1.1, and ASME codes and standards.
• Ability to validate numerical results with classical hand calculations and engineering judgment.
• Strong technical writing, organizational, and communication skills, with the ability to work effectively with internal and external stakeholders.

• Master of Science in Mechanical, Structural, or Aerospace Engineering, with an emphasis in structural mechanics, solid mechanics, or computational/finite element methods.
• Demonstrated experience evaluating dynamic response, wind-inducted vibrations (VIV, galloping) in slender cantilevers members.
• Advanced proficiency with ANSYS.

• Serve as the subject matter expert for FEA within the Engineered Structures team, with real influence on analysis methods, standards, and procedures.

• Opportunity to join a well-established business with a strong reputation and growing customer base.
• Lead the FEA function and shape how analysis is performed on complex models as the in-house engineering team grows.

• Competitive salary commensurate with experience and education, plus performance-based bonus eligibility.
• Medical, dental, and vision insurance.
• 401(k) retirement plan with company match.
• Paid time off and paid holidays.
• Professional development support, including software training, PE licensure, and continuing-education reimbursement.

This position may require up to 10% travel. Employment is contingent on successful completion of a pre-employment physical examination/medical history check. A valid Texas driver’s license is required. Race Rock is an Equal Opportunity Employer.