Precision-
Installed.
Exposed to
Proof.

A 400-ton kraft pulping line seized at 2 a.m. on a Monday. The gearbox had spun a bearing and scored the housing. Unplanned downtime was costing the mill $18,000/hour.

Our crew rigged the 6.2-tonne gearbox out with strand jacks, machined the housing in-situ with a portable boring bar, pressed new bearings, and re-installed with laser alignment verified to manufacturer tolerances before the day shift arrived.

Line back online in 68 hours. Alignment verified at ±0.0005″ across all planes. Zero repeat failures in 14 months of follow-up.

A 180 MW combined-cycle plant had been running 0.008″ out of parallel on the turbine-generator coupling for two scheduled outages. Vibration was trending upward — bearing replacement was becoming quarterly.

Installed reverse-indicator dial brackets, mapped thermal growth across four operating temperatures, calculated cold-offset targets, and shimmed the generator to bring the drive train within 0.0015″ of true at operating temperature. Documented every reading with time-stamped data logs.

Vibration amplitude down 61%. Bearing interval extended from 90 days to 18 months. Plant accepted our alignment report as the new baseline standard.

A new copper concentrator needed a 28-tonne SAG mill set on a 3.2 m elevated concrete foundation. The civil contractor delivered the anchor bolts 3 mm out of pattern — 6 days before the mechanical crew's mobilization window.

Core-drilled and re-epoxy-anchored four of twelve bolts to correct the pattern, laser-levelled the sole plates to within 0.002″ over a 4.8 m span, set the mill shell in two sections with a 500-tonne mobile crane, and grouted with high-strength non-shrink. All work inspected by the owner's QA engineer on site.

Handover 2 days ahead of revised schedule. Foundation survey showed zero settlement after first 90 days of operation. Retained for Phase 2 ball mill installation.

A head pulley bearing failure took down a 340 m overland conveyor carrying automotive stampings between two press buildings. Second shift was idled. Production scheduled to resume at 6 a.m.

Mobilized a 3-man crew at 10 p.m. with a pre-staged bearing kit. Removed the head pulley assembly, pressed new spherical roller bearings with a hydraulic puller set, checked pulley lagging, re-installed and laser-aligned the pulley to the carry idlers, tensioned the belt, and ran a no-load test before handing back to maintenance.

Conveyor running by 4:45 a.m. — 75 minutes before first shift. No lost production. Client added us to their approved emergency maintenance roster.