Casting Yard Inspector

The Casting Yard Inspector plays a key role in ensuring the quality and compliance of precast reinforced concrete segments produced for elevated light rail systems. This role is responsible for inspecting every stage of the manufacturing process to verify that all materials, fabrication procedures, dimensional tolerances, and finished products meet the standards set by approved drawings, specifications, and quality requirements. The inspector's work is crucial to achieving successful delivery and erection of precast segments.

Inspection & Quality Control

• Inspect precast reinforced concrete segments throughout all stages of production, including:
  • Reinforcement placement and detailing
  • Embedments, inserts, ducts, and post-tensioning components
  • Formwork setup and dimensional accuracy
  • Concrete batching, placement, consolidation, and finishing
  • Curing processes and stripping operations
• Verify compliance with approved shop drawings, method statements, and inspection test plans (ITPs).
• Check dimensional tolerances, surface finishes, chamfers, match-cast faces, and alignment features.
• Identify and document defects such as cracks, honeycombing, voids, surface blemishes, and exposed reinforcement.

Materials & Testing

• Confirm that all materials (cement, aggregates, admixtures, reinforcement, prestressing strands) meet approved submittals and project specifications.
• Witness and record results of key concrete tests, including:
  • Slump/flow tests
  • Air content
  • Temperature
  • Compressive strength (cube/cylinder tests)
• Monitor curing regimes (steam or wet curing) and ensure strength gain requirements are satisfied prior to demolding or stressing.

Documentation & Reporting

• Maintain accurate and detailed inspection records, checklists, and daily reports.
• Issue non-conformance reports (NCRs) for any non-compliant work and verify that corrective actions are implemented.
• Review and endorse quality documentation, test results, and production records.
• Coordinate with quality assurance teams, engineers, and production staff to resolve any quality issues.

Safety & Compliance

• Ensure all casting yard operations comply with project safety plans and relevant regulations.
• Immediately report any unsafe conditions or practices.
• Promote a culture of quality and safety awareness among all casting yard personnel.

Coordination

• Liaise with engineers, designers, production supervisors, and client representatives as needed.
• Support audits, inspections, and factory acceptance tests (FATs).
• Verify that precast segments are properly stored, handled, labeled, and ready for transportation.

Education

• Diploma or Degree in Civil Engineering, Construction Technology, or a related field (preferred).

Experience

• 3-7 years of experience in precast concrete inspection or quality control.
• Demonstrated experience with precast or prestressed concrete segments for bridges, viaducts, or rail infrastructure.
• Familiarity with match-cast segmental construction is an advantage.

Technical Knowledge

• Strong understanding of:
  • Reinforced and prestressed concrete
  • Segmental bridge construction
  • Concrete testing standards (e.g., ASTM, BS, EN, ACI)
  • Dimensional tolerance requirements for rail structures
• Ability to read and interpret construction drawings and technical specifications.

• Keen attention to detail and quality
• Strong documentation and reporting skills
• Effective communication and coordination abilities
• Ability to work independently in a production environment
• Problem-solving and analytical mindset

• Based primarily at a precast casting yard or precast facility.
• Flexibility to work extended hours, night shifts, or weekends to support production schedules as needed.
• Regular exposure to industrial environments, heavy equipment, and concrete production activities.

This position requires a proactive and detail-oriented individual capable of maintaining rigorous quality standards and supporting a safe, collaborative work environment. Flexibility and adaptability to production demands are essential for success.