industrial coatings

Crankshaft Repair

A power generation company recently entrusted us with the repair of an 8,000 lb crankshaft, a critical component in their operations. The crankshaft, which had a worn journal, required specialized attention to restore it to optimal condition. Our Machining Services team began by carefully prepping the worn journal, ensuring it was ready for the next phase. Horner Industrial Coatings then applied a 420 stainless steel coating to the journal. This material was chosen for its durability and machinability, providing a robust yet workable surface. Once the coating process was complete, our Machining Services team machined and polished the journal to meet [...]

Crankshaft Repair2025-07-24T11:01:54-04:00

Steel Mill Exhaust Fan Tests New Loctite Coating

Horner Industrial Coatings recently addressed an issue concerning a steel mill exhaust fan that required coating following modifications to its design. The customer reported encountering challenges related to particle accumulation on the backside of the fan blades due to the structural design of the gussets supporting each blade. In response, our Fan/Fab team redesigned the support structure and conducted all necessary welding tasks prior to coating. Given that the blades were already hard-faced, our standard process of applying a hard coat was deemed unnecessary. Instead, we opted to coat the entire fan with a zinc-based wire, effectively galvanizing it and providing [...]

Steel Mill Exhaust Fan Tests New Loctite Coating2025-07-23T12:11:20-04:00

High Wear Environment Bowls – Industrial Coatings

The presence of a duplicate part submitted for repair serves as a testament to the quality of our workmanship. Specifically, we have recently received the top section of a bowl assembly, an item that has been a recurring client in our facility. These bowl assemblies play a critical role in the processing of grain slurry, a substance known for its erosive tendencies, causing wear and deterioration from within the components. To facilitate the repair we had to cut out about a 16-inch section of bronze and cut a new piece to put in its place. Once the new piece of bronze [...]

High Wear Environment Bowls – Industrial Coatings2024-11-15T12:56:02-05:00

Coatings for Coal Metering Plates

          An aggregate company that manufacturers cement uses coal to feed a burner that is used in the concrete making process. This coal is metered or measured before going into the burner. The 4 foot plate used in the metering machine gets worn out quickly and Horner Coatings was tasked with making the part last longer. Coatings took the metering plates and built them back up to the proper thickness with 420 stainless steel to provide the hardness to make it last. Another part looks like a honeycomb had to be sprayed using two people spraying at [...]

Coatings for Coal Metering Plates2024-02-28T10:19:20-05:00

Manufacturing Plates Only Lasting A Few Weeks

A local concrete manufacturer came to us with a wear problem on their plates which are used to screen up to 300 tons per hour of raw product to size during the manufacturing process. The plates were only lasting a few weeks so they contacted Horner Coatings. Fan and Fabrication fabricated a new plate then it was sent back to us to be grit blasted and we bond coated the raw metal with an iron aluminum alloy which is made to go down coarse. This gives the wear material a better surface to bond with. Loctite 7332 and 7227 were the [...]

Manufacturing Plates Only Lasting A Few Weeks2023-06-07T10:26:47-04:00

Horner Coatings Keeps Plastic Shopping Bags In Production

A plastics company called us out to examine two shafts used on the wash line hopper on their recycled product lines. They take used plastic and create new hard pellet material that combine with other raw materials to make plastic bags used for retail. This hopper is the first in the wash line where the material is cleaned. These small shafts have a dual bushing design that in theory, should be grease lubricated and would wear as the machine operated. This would lead to the eventual need to replace bushings on the shafts but that would have been anticipated by Preventative [...]

Horner Coatings Keeps Plastic Shopping Bags In Production2022-05-16T10:36:48-04:00

Environmental Gas Company Repair

An Environmental facility on the southside of Indianapolis draws gases off the large Landfill next door. They then filter, clean and dry the gas and then sells they turn around and sell the flammable gas to Utility companies. Our first call came in to help them with a pilot bearing replacement in the bottom of a tank that holds a mixer blade in place that mixes a solution that scrubs the methane gas to make it cleaner before it is sent to their customer as fuel. Horner’s Field Service Technicians on site discovered a lot of problems going on. The pilot [...]

Environmental Gas Company Repair2021-02-18T18:47:10-05:00

Cement Plant Fan on a Kiln

A Cement Plant in Ohio had a fan that is subjected to major abrasive wear due to the particulate in the atmosphere at the plant. Erosion on this fan causes this but they found it worse than normal. This was found during a short outage on a Kiln. Horner Fan and Fab and Horner Machining Services worked together to make this job a success. Heidi and Darrel worked together with their teams to pull off an amazing amount of highly skilled decisions and experienced work to make this job come together in the  time frame we were given. Right down to [...]

Cement Plant Fan on a Kiln2021-01-10T16:41:03-05:00

Coated Spool for Chemical Plant Praises Coatings

It’s nice to hear from customers time to time whenever something works better than they expected. A chemical company came to Horner Coatings with a problem a couple years ago. The problem: a double flanged spool part that attached to an absorption tower with a pipe that enters the tower to aid in protection of the tower nozzle. The material in the pipe is SO2 gas and there is some water present from the blowers that supply air for combustion. When the water and SO2 react they make sulfurous and sulfuric acid. The spool was only lasting 8-10 weeks before having [...]

Coated Spool for Chemical Plant Praises Coatings2021-01-09T21:40:55-05:00

Keeping a Plane Safe at 35,000 Feet

Aircraft Engines are the beating heart of an airplane. We, as passengers expect them to run free of mechanical errors and keep us safe in the air no matter what happens: bad weather, geese, etc. The manufacturers of these engines test them extensively to make sure they are built well. Horner gets to be involved somewhat in keeping those testing facilities up and running. An aircraft engine manufacturer needed repair and maintenance on a 6,000 HP Compressor Motor. The compressor furnishes air for testing aircraft engines. It is run on a Dynometer which we have also repaired in the past. The [...]

Keeping a Plane Safe at 35,000 Feet2021-01-09T00:04:12-05:00

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