diff --git a/app/utils/pdf_export.py b/app/utils/pdf_export.py
index 57a2943..e7549cd 100644
--- a/app/utils/pdf_export.py
+++ b/app/utils/pdf_export.py
@@ -351,6 +351,7 @@ def _form_fields_section(form_fields, form_data, static_folder):
             if ft in _ALWAYS_SHOW_PRE:
                 return True
             if ft == 'rating'        and str(v).isdigit() and int(v) > 0:  return True
+            if ft == 'pass_fail'     and v:                                 return True
             if ft == 'checkbox'      and v in ('yes','true'):               return True
             if ft == 'checkbox_group'and isinstance(v, list) and v:        return True
             if ft == 'image'         and v and os.path.exists(os.path.join(static_folder, v)): return True
@@ -398,14 +399,48 @@ def _form_fields_section(form_fields, form_data, static_folder):
         # Build one Table row with cells sized by colSpan.
         # Fields with no value are skipped unless they are text/textarea/label —
         # those always appear so free-text notes are never suppressed.
-        cells      = []
-        col_widths = []
+        # current_col tracks horizontal position (1-based) so gaps between fields
+        # are filled with invisible placeholder cells that preserve column alignment.
+        cells       = []
+        col_widths  = []
+        has_content = False
+        current_col = 1
+
+        # Returns True if the field should be hidden from the PDF.
+        def _skip(ftype, val):
+            if ftype == 'rating':
+                return not str(val).isdigit() or int(val) == 0
+            if ftype == 'image':
+                img_path = os.path.join(static_folder, val) if val else ''
+                return not val or not os.path.exists(img_path)
+            if ftype == 'signature':
+                return not val or not str(val).startswith('data:')
+            if ftype == 'checkbox':
+                # stored as 'true'/'false' by _collect_form_responses
+                return val not in ('yes', 'true')
+            if ftype == 'pass_fail':
+                return not val
+            if ftype == 'checkbox_group':
+                return not val or not isinstance(val, list) or len(val) == 0
+            if ftype == 'table':
+                return not val or not isinstance(val, list) or len(val) == 0
+            # All remaining input types (text, textarea, number, date,
+            # email, radio, select, and any future types)
+            return not val
 
         for field in fields_in_row:
             ftype    = field.get('type', '')
+            col      = field.get('col', current_col)
             col_span = field.get('colSpan', 1)
             cell_w   = UNIT * col_span
 
+            # Fill horizontal gap before this field with an invisible spacer
+            if col > current_col:
+                gap_w = UNIT * (col - current_col)
+                cells.append(Paragraph('', STYLES['FieldValue']))
+                col_widths.append(gap_w)
+            current_col = col + col_span
+
             # ── Inline label (free-standing text element) ─────────────────────
             if ftype == 'label':
                 fs_map = {'small': 8, 'normal': 9, 'large': 11, 'x-large': 13}
@@ -418,6 +453,7 @@ def _form_fields_section(form_fields, form_data, static_folder):
                 )
                 cells.append(p)
                 col_widths.append(cell_w)
+                has_content = True
                 continue
 
             fid = str(field.get('id', ''))
@@ -425,29 +461,10 @@ def _form_fields_section(form_fields, form_data, static_folder):
             lbl = field.get('label', '')
 
             # ── Skip fields with no meaningful value ──────────────────────────
-            # Returns True if the field should be hidden from the PDF.
-            def _skip(ftype, val):
-                if ftype == 'rating':
-                    return not str(val).isdigit() or int(val) == 0
-                if ftype == 'image':
-                    img_path = os.path.join(static_folder, val) if val else ''
-                    return not val or not os.path.exists(img_path)
-                if ftype == 'signature':
-                    return not val or not str(val).startswith('data:')
-                if ftype == 'checkbox':
-                    # stored as 'true'/'false' by _collect_form_responses
-                    return val not in ('yes', 'true')
-                if ftype == 'pass_fail':
-                    return not val
-                if ftype == 'checkbox_group':
-                    return not val or not isinstance(val, list) or len(val) == 0
-                if ftype == 'table':
-                    return not val or not isinstance(val, list) or len(val) == 0
-                # All remaining input types (text, textarea, number, date,
-                # email, radio, select, and any future types)
-                return not val
-
             if _skip(ftype, val):
+                # Keep a placeholder so subsequent fields stay in column position
+                cells.append(Paragraph('', STYLES['FieldValue']))
+                col_widths.append(cell_w)
                 continue
 
             lbl_p = Paragraph(lbl, STYLES['FieldLabel'])
@@ -479,7 +496,9 @@ def _form_fields_section(form_fields, form_data, static_folder):
                                     height=1.0 * inch,
                                     kind='proportional')
                 except Exception:
-                    # Could not load image — skip this cell entirely
+                    # Could not load image — insert placeholder to preserve column position
+                    cells.append(Paragraph('', STYLES['FieldValue']))
+                    col_widths.append(cell_w)
                     continue
 
             elif ftype == 'signature':
@@ -536,9 +555,10 @@ def _form_fields_section(form_fields, form_data, static_folder):
 
             cells.append(box)
             col_widths.append(cell_w)
+            has_content = True
 
-        # Skip the entire row if nothing made it through the filter
-        if not cells:
+        # Skip the entire row if no field had meaningful content
+        if not has_content:
             continue
 
         row_tbl = Table([cells], colWidths=col_widths, hAlign='LEFT')