In this episode, I talk with Carlos Banchik, P.E., CEO and Chairperson of the Board at Innova Technologies Inc., about tackling global monorail engineering challenges with creative solutions. We explore what it takes to design monorail systems that combine structural precision, complex geometry and multidisciplinary integration, including seismic retrofits and sustainable transit infrastructure. You’ll also hear how leadership development and ESOP ownership are transforming technical teams into purpose-driven innovators.
Here Are Some of the Questions We Ask Carlos Banchik, P.E.:

What does it take to design a monorail that spans cities and handles extreme environmental demands?
What unique structural engineering challenges arise in large-scale monorail infrastructure projects and how are they solved?
How can technical excellence, construction safety, cost and sustainability be balanced in monorail design?
What can be learned from working on seismic retrofit and alignment-focused engineering projects?
How do engineers successfully manage international monorail projects across multiple codes, cultures and stakeholders?
How do monorail systems support sustainable cities and reduce CO2 emissions?
How are monorail guideway beams constructed and how does formwork align with tight structural tolerances?
Why did you decide to move your firm toward employee ownership through an ESOP and how does it empower engineers?
What advice helps engineers become leaders while maintaining their technical engineering edge?
What final insight would you offer to engineers who want to make a meaningful impact on their communities and the world?

Here Are Some of the Key Points Discussed About Designing Monorail Systems to Solve Real Engineering Challenges


Designing urban monorail systems demands precise structural alignment, tight construction tolerances and proactive collaboration between disciplines like power, mechanical and structural engineering. Every beam must integrate infrastructure needs while delivering mobility solutions built to withstand urban and environmental stressors.
Monorail engineering challenges include geometric alignment, mechanical integration and sustaining 100-year service life with minimal deflection. These challenges are met by aligning civil, electrical and mechanical systems within strict millimeter tolerances for strength and safety.
Delivering smart infrastructure requires early stakeholder engagement and a detailed understanding of every stakeholder’s requirements, from transit planners to construction teams. Success comes by weaving together different disciplines into one seamless solution tailored to performance and long-term serviceability.
Working across disciplines in seismic retrofit and alignment-based projects teaches engineers how to listen, adapt and unify diverse solutions into constructible designs. These experiences build leadership insight, technical confidence and innovative thinking that leads to better structural outcomes.
Managing international monorail projects starts by studying the host country’s regulatory framework, identifying local experts and combining global engineering standards with regional context. Multinational success depends on language fluency, cultural awareness and teamwork that bridges diverse skills and expectations.
Compared to subways and traditional rail, monorail structures use up to 40% less concrete and 10% less steel while offering significantly faster construction speeds. Monorails deliver cost-effective, lower-emission transit options for high-density cities seeking sustainable infrastructure.
Most monorail guideway beams are precast using advanced adjustable formwork systems capable of casting both straight and curved beams. Geometry and finish are fine-tuned through model...