6 Lessons Learned from 40 Years of Prestressing in Asia
1. Understand Local Conditions Before Applying Global Solutions
Prestressing technology may be global, but its success on-site depends heavily on local context. I learned early that designs and methods developed in Europe or the U.S. must be adapted to fit the realities of construction in Asia—climate, workforce skill level, construction culture, and material availability all matter.
Case in point: When we introduced the individually PSS stay cable system in Cebu, Philippines, it wasn’t just about bringing in a new product. We had to localize testing protocols, build trust with local engineers, and train crews on techniques they had never used before.
Lesson: Effective engineering in Asia starts with cultural and technical adaptation—not just technology transfer.
2. Value Engineering Is Not Just About Cost Reduction
Too often, value engineering is misunderstood as cutting corners. In truth, it's about optimizing a project for performance, constructability, and lifecycle value.
Example: On the Venetian Macau podium project, we re-engineered the structure and saved over 30% in steel reinforcement—without compromising performance or safety. That success came from collaboration, not confrontation, with the designer and contractor.
Lesson: Bring value engineering in early, make it collaborative, and focus on value, not just cost.
3. Training Is the Foundation of Sustainable Quality
When we entered the post-tensioning market in Vietnam in 2008, there was virtually no local capability. Instead of importing an expat workforce, we hired and trained local engineers, site supervisors, and installers. Within a few years, our local team secured over 50% of the market share.
Lesson: Technical systems are only as good as the people who install and maintain them. Invest in training—it pays back many times over.
4. Details Matter—Especially at the Anchorages
In external PT systems, most long-term problems occur not in the tendons, but at the anchorages. Misaligned ducts, incomplete grouting, and inadequate detailing can all lead to premature deterioration and expensive repairs.
We are now seeing the consequences of improperly grouted anchorages in early-generation PT projects. In several recent consultancy assignments, we've had to design complex interventions to restore performance where proper detailing and execution could have prevented the issue entirely.
Lesson: Never underestimate the importance of good detailing and thorough quality control—especially where it’s difficult to inspect after the fact.
5. Innovation Isn’t Optional—It’s How You Survive
In Hong Kong’s highly competitive viaduct sector, we delivered more than 10 km of segmental deck using launching gantries and lifting frames under tight schedules. Our team often had to design and build equipment ourselves because no standard system could do the job.
Lesson: There’s always room to innovate—whether it’s in methods, equipment, or sequencing. Creativity on site is just as important as design excellence.
6. Good Joint Ventures Are Built on Shared Values
Technical expertise matters, but successful joint ventures rely on trust and alignment. Whether working in Vietnam, the Philippines, or Hong Kong, I found that the most durable partnerships weren’t just commercial—they were based on shared technical standards, openness, and a willingness to learn from each other.
Lesson: Choose partners who align with your principles and are willing to grow together. That’s the real foundation of long-term success.
Bonus Tips for Young Engineers
To those starting their journey in prestressing or civil infrastructure:
- Be curious. Ask why, not just how.
- Go to site. That’s where real engineering happens.
- Respect the tradespeople—they know more than you think.
- Understand the systems you work with, not just the drawings.
- Never stop learning.
Closing thoughts
After 40 years, I’m still learning. Technology evolves, markets change, but the fundamentals of good engineering—clarity, precision, collaboration, and adaptability—remain constant.
If you’re dealing with post-tensioning challenges, tendon inspections, or looking to bring innovation to your infrastructure projects, feel free to reach out. I’d be glad to share what I’ve learned—or help you avoid some of the mistakes I’ve already made.
💬 Let’s Talk
Have you encountered similar challenges in your PT or bridge projects?
📧 Contact michel(@)monballiu.net today !