Rob Donovan - Rob Donovan

Robert Darren "Rob" Donovan, played by Marc Baylis, made his first screen appearance during the episode broadcast on 9 July 2012. Rob is the estranged brother of Carla Connor (Alison King). Rob was originally named "Darren" and had previously been mentioned in the series and by cast and crew members during interviews. He was not in Carla's life as he was serving an eight-year stint in Strangeways prison for armed robbery. In 2008, the serial's executive producer Kim Crowther told Kris Green from Digital Spy that her team had discussed the character. She said that there were no plans to introduce him, but it was likely that he would appear in the future. While King told Green that she imagined Carla's brother to be "stunningly charming, but a complete minger inside". She explained that he was likely to be "rough as old boots" because they are from a "really rough family". She added that Carla would have "a brother who's absolutely brilliant with her". Coronation Street fans later got the wrong impression that Luke Strong (Craig Kelly) was Carla's brother. In 2010, King told Green that she always expressed her interest in him joining the series but nothing came of it. She said that she would like him to come and live with Carla and "get off with" Michelle Connor (Kym Marsh).

In March 2012, the serial announced that their intention to introduce Rob and started the casting process. A Coronation Street representative said that they were going to see "lots of different actors" audition for the role. They also planned "exciting storylines" because fans had "been keen to meet for some time". A writer from itv.com said that Rob will "turn heads and break hearts as the new moody bad lad of the Street". Rob will "ruffle a few feathers" and "waste no time in setting his sights on some of Coronation Street's most eligible women". Among those who auditioned for the role was Jamie Lomas; while actor Marc Bannerman also expressed his interest in the part. However, Baylis was cast in the role and his casting was announced on 3 May 2012. Of joining the soap, Baylis said "I feel incredibly honoured to be joining the very talented cast of Coronation Street. Rob is an exciting character to play and I am hoping he is going to ruffle a few Weatherfield feathers." Coronation Street's producer Phil Collinson added that he was pleased to welcome Baylis to the cast and branded him "the latest in a long line of handsome Corrie charmers." Rob arrives in Weatherfield after being in prison and he seeks Carla's help to make a fresh start. Collinson said Rob would "set hearts fluttering" and he soon develops a reputation as a ladies man, especially when he sets his sights on Eva Price (Catherine Tyldesley). A writer for itv.com's official Coronation Street website described Rob as "a bit of a rogue with a twinkle in his eye", while Collinson called him a "handsome bad boy". When asked by Digital Spy's Daniel Kilkelly about the character's name, Collinson revealed that Darren is Rob's middle name and that Carla does not have another brother.

When Carla and Peter leave Weatherfield for Los Angeles, Rob steps in to help Michelle run the factory. Shortly after Carla and Pater return for Christmas, Carla announces that she is going back to LA and selling the factory to the highest bidder. Knowing that he cannot find the money to make a bid, Rob decides to cook the books so the broker gives them a low valuation. When Carla returns for good, Rob and Michelle worry they will be caught out. Carla does find out and sacks Rob, threatening to report him for fraud. Rob goes into business for himself, stealing clients and orders from Underworld. Realising that she cannot beat Rob at his tricks, Carla offers Rob 45% share in the factory, much to Michelle's disliking.