Shaft misalignment can cause major problems—excessive vibration, bearing failure, coupling damage, and energy loss. These challenges are common in rotating machinery across industries, from power generation to manufacturing and industrial operations.
At ROTATEK, we specialize in solving these issues with expert laser shaft alignment services. Our alignment engineers use cutting-edge laser alignment systems to deliver pinpoint accuracy, ensuring shafts are perfectly aligned to OEM tolerances. We account for thermal growth, dynamic loads, and real-world operating conditions—providing lasting alignment solutions, not just temporary fixes.
Whether you’re commissioning new equipment or troubleshooting performance issues, ROTATEK’s laser shaft alignment services restore reliability, extend asset life, and reduce costly downtime.
When precision matters, ROTATEK delivers.
how Can we Help you?
Our expert team is ready to help you with your next project. Explore the industries we serve or contact us to learn more.
Shaft alignment is the process of precisely aligning the rotational centers of two or more connected machines—typically a driver (like a motor) and a driven component (like a pump or gearbox)—so that they are colinear during operation. When shafts are properly aligned, they rotate smoothly without introducing undue stress, vibration, or wear.
In rotating equipment like pumps, motors, turbines, and compressors, even minor shaft misalignment can cause major problems. Misalignment increases vibration, causes premature bearing and seal failures, and leads to energy losses and unplanned downtime. Precise shaft alignment ensures optimal operation, minimizes mechanical wear, and supports long-term equipment reliability.
Misalignment leads to uneven load distribution across rotating elements. Over time, this results in accelerated bearing degradation, shaft fatigue, and elevated operational temperatures. Precision shaft alignment ensures shafts are co-linear during rotation, reducing radial and angular misalignment to within OEM recommended tolerances.
Misalignment occurs when the rotational centers of two connected shafts are not perfectly co-linear. Even small deviations can have significant mechanical consequences, including vibration, premature wear, and energy inefficiency. Below are the primary types of shaft misalignment we identify and correct using precision laser alignment equipment.
Using advanced laser shaft alignment systems, we can detect and quantify each type of misalignment with high precision—down to thousandths of an inch. Our alignment engineers then calculate precise mechanical adjustments (shimming, moving, leveling) to correct the alignment, followed by verification measurements and documentation.
Our shaft alignment service follows a proven, methodical process to ensure your rotating equipment performs with maximum reliability and efficiency. Here’s our general approach and how we deliver fast, accurate, and documented results:
Step 1: Pre-Alignment Inspection & Preparation
Job-site safety analysis and lockout/tagout procedures.
Visually inspect machines, couplings, mounts, baseplates, and surrounding equipment.
Check for soft foot using dial indicators or laser tools.
Assess any foundation issues or structural concerns.
Verify machine cleanliness and accessibility for measurement tools.
Why it matters: Misalignment correction is only effective when root causes—like base distortion or pipe strain—are addressed first.
Step 2: Precision measurement with laser alignment systems
Collect baseline measurements of both horizontal and vertical misalignment.
Identify parallel (offset) and angular errors.
Apply thermal growth targets if applicable.
Why it matters: Laser alignment ensures high-resolution data—far more accurate than traditional dial indicator methods.
Step 3: mechanical alignment corrections
Adjust machine foot positions by adding or removing precision shims.
Use jacking bolts or fine-tuning adjustments to move equipment horizontally and vertically.
Monitor each adjustment in real time to track progress toward tolerance targets.
Why it matters: Laser alignment ensures high-resolution data—far more accurate than traditional dial indicator methods.
Step 4: verification and final alignment check
Perform a complete re-measurement to verify corrections.
Ensure alignment falls within manufacturer or industry-standard tolerances.
Confirm that soft foot has not returned during the adjustment process.
Conduct a rotational sweep to detect coupling or shaft anomalies.
Why it matters: Verifying the alignment ensures sustainable results and catches any last-minute issues before equipment is placed in-service.
Step 5: documentation and reporting
Provide a full alignment report with before-and-after results.
Include tolerance levels, correction data, and technician notes.
Optional thermal growth charts or vibration readings if collected.
Why it matters: Clear documentation supports quality control, audits, and future maintenance planning.
optional: THERMAL GROWTH / DYNAMIC MOVEMENT ANALYSIS
For critical equipment, we offer thermal growth / dynamic movement analysis, cold-hot alignment monitoring, and live-tracking during operation.
Identify movement caused by load, speed, or temperature changes.
Why it matters: Real-world conditions often reveal misalignments that static alignments can’t detect. We address both.
Proper shaft alignment is essential for maximizing equipment reliability and performance. By ensuring that rotating shafts are precisely aligned, you reduce mechanical wear, minimize vibration, lower energy consumption, and extend machine life. This results in fewer unexpected breakdowns, improved workplace safety, and increased operational efficiency—saving time and money across your facility.
1. REDUCED EQUIPMENT WEAR AND TEAR
Misalignment causes undue stress on bearings, seals, shafts, and couplings. Proper alignment minimizes mechanical strain, extending the life of components
2. LOWER ENERGY CONSUMPTION
Misaligned shafts cause machines to work harder, increasing power draw. Precision alignment reduces friction and resistance, improving energy efficiency.
3. mINIMIZED VIBRATION AND NOISE
Proper alignment significantly reduces vibration and noise, which are indicators of stress and potential failure in rotating machinery.
4. FEWER UNPLANNED DOWNTIME
Misalignment often leads to unexpected failures. Accurate alignment helps prevent breakdowns, improving equipment reliability and uptime.
5. EXTENDED MACHINE LIFE
By preventing premature failure of components, precision alignment maximizes the return on investment in machinery.
6. IMPROVED SAFETY
Well-aligned equipment operates more smoothly and reliably, reducing the risk of accidents caused by mechanical failures.
7. INCREASED PRODUCTIVITY
Efficient, trouble-free machines lead to fewer interruptions, enabling consistent and higher output levels.
8. COMPLIANCE WITH OEM STANDARDS
Most manufacturers require alignment within specified tolerances to validate warranties and ensure optimal performance.
9. OPTIMIZED MAINTENANCE SCHEDULING
Precision alignment allows for more predictable and planned maintenance intervals, avoiding reactive or emergency repairs.