Resident Engineer - Corrosion

Location: South Yorkshire

Engagement: Contract

Working pattern: Predominantly site-based

The Opportunity

We are seeking an experienced Resident Engineer - Corrosion to represent the Client’s interests during a major rail vehicle Fleet Life Extension Programme.

The condition and extent of corrosion vary across the vehicle fleet. Each vehicle will require a structured inspection and engineering assessment before the appropriate repair scope can be agreed.

Acting as the Client’s primary technical representative at the repair facility, you will provide independent oversight of corrosion inspections, structural repairs and quality assurance. You will ensure that all work is completed safely, consistently and in accordance with approved engineering specifications, drawings, procedures and applicable standards.

This is a hands-on role requiring strong technical judgement, attention to detail and the confidence to challenge repair proposals or workmanship that does not meet the required standard.

Key Responsibilities

• Represent the Client’s technical interests at the vehicle repair facility.
• Witness and undertake detailed inspections of vehicle bodyshells, underframes and associated structural areas.
• Assess the location, type and extent of corrosion on each vehicle.
• Verify defect mapping, material-thickness measurements, inspection findings and condition classifications.
• Identify areas requiring additional cleaning, stripping, access, measurement or non-destructive testing.
• Review and agree a proportionate vehicle-specific repair scope based on measured condition and approved acceptance criteria.
• Determine whether affected areas require cleaning and protective treatment, local repair, reinforcement, sectional replacement or more substantial structural intervention.
• Review repair specifications, drawings, engineering instructions, method statements and inspection and test plans.
• Ensure repair proposals are approved by the appropriate design or technical authority before implementation.
• Witness defined inspection and repair hold points.
• Monitor structural repair activities, including material removal, cutting, forming, welding, fastening, sealing and protective-coating application.
• Confirm repair materials meet the required grade, thickness and specification and have appropriate certification and traceability.
• Review welding procedures, welder qualifications, inspection results and relevant non-destructive testing records.
• Identify non-compliant work and require appropriate corrective action.
• Review technical queries, deviations, concessions and proposed alternative repairs.
• Recommend that work is paused, rejected or withheld from acceptance where safety, structural integrity or quality could be compromised.
• Maintain clear and auditable records, including inspection reports, photographs, technical decisions, non-conformances and repair completion evidence.
• Provide regular progress reports and early warning of issues affecting safety, quality, cost, programme or fleet availability.
• Complete final inspections and provide an engineering recommendation for vehicle acceptance and return to service.

About You

You will have substantial experience in corrosion inspection, structural assessment and repair within rolling stock, rail vehicles or another safety-critical engineering environment.

You should have:

• Strong knowledge of corrosion mechanisms affecting metallic structures.
• Experience of bodyshell, chassis, underframe or load-bearing structural repairs.
• Knowledge of welding, NDT, surface preparation and corrosion-protection systems.
• Experience managing inspection hold points, non-conformances and technical concessions.
• The ability to interpret drawings, repair instructions and engineering standards.
• Strong reporting, stakeholder-management and contractor-assurance skills.
• Independent engineering judgement and the confidence to challenge unsuitable repairs.