Stadler Rail operates and maintains the Class 745 and 755 fleets for Greater Anglia across East Anglia, a network which demands consistently high standards of presentation and asset condition. With a significant programme of paintwork repairs required, Stadler needed a partner who could mobilise quickly, work within the constraints of a live operational depot, and deliver to precise specifications.
The scope of the project covered external touch-in and smart paint repairs across 31 trains, working to Stadler’s quality standards and their Smart Paint Repair Procedure. All works were to be carried out at the Clacton-on-Sea depot, with vehicles made available one unit at a time across a Monday to Friday window. Every repair needed to meet strict acceptance criteria covering exterior bodysides, cab fronts, and door surfaces, with full documentation required throughout.
Within six working days of contract award, Aura mobilised a 10-person paint team, appointed a dedicated project manager, and secured all required equipment and consumables. Working to Stadler’s specification, the team delivered touch-in and smart repairs to every unit, with all work quality checked before sign-off.
The original programme of one unit per week expanded to two units as confidence in the process grew. This required extended working hours and weekend shifts, with Aura adapting quickly to meet the increased output without any reduction in quality. A bespoke reporting system was developed to meet Stadler’s specific documentation requirements, with a dedicated coordinator providing daily progress updates. Full records, including batch numbers, paint thickness measurements, operative sign-offs, and before-and-after imagery, were provided for each completed unit.
Some rakes involved over 1,000 individual repairs, requiring exceptional attention to detail and consistent on-site management throughout.
The programme ran from April to October, with every one of the 31 trains, 21 four-car and 10 three-car units, completed to a 100% pass rate. Across the full programme, over 17,000 individual defects were identified and repaired, all delivered on-site at Clacton-on-Sea, hitting the operational targets set by Stadler.
The tailored reporting system developed for this project gave Stadler complete oversight of all repair activity, providing full confidence in the condition of their fleet, and a clear record for long-term asset management.
