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machining services

Aggregate Dredge Shaft

We were contacted by a sand and gravel producer in hopes that we could make a drive shaft that was accidentally bent and running out of balance. The original plan was for the end user to purchase the coupling hubs and have Horner Machining Services install those onto the new tubing. Once the customer finally received the Hubs from the Original Manufacturer they were incorrect. At that point, and having waited beyond the expected delivery date, our customer asked if Machining Services could machine new hubs from blank stock. Darrell Cothron and his team accepted the challenge and began the overtime [...]

Aggregate Dredge Shaft2023-03-14T11:34:52-04:00

Slip Ring Rebuild

A customer called overnight because they had a slip ring failure on one of two synchronous motors and that halted production. Horner was on site in the morning to assess the situation and it was determined that an on site repair was not feasible. The unit was disassembled and transported to the Terre Haute shop for rebuild. By securing customer supplied brushes, brushholders (which are now obsolete), Horner stock to fabricate insulators and with the help of Horner Machining Services, we were able to have the unit back on site within just a few days. Horner was onsite for the eight [...]

Slip Ring Rebuild2023-03-03T11:44:31-05:00

Steel Rolling Tandem Mill Motor

A steel manufacturer sent in a steel rolling tandem mill motor after the armature equalizer insulation had failed to ground due to age and time of service. The bearings, bearing journals, and bearing housings were severely damaged. A team of different Horner Divisions came together to complete this project. Machining Services did an extensive amount of machine work on the shaft and bearing housing. They also turned and undercut the armature when the rewind was completed. Fan and Fabrication manufactured new bearing seal inserts. Horner Coatings sprayed and machined the shaft and bearing housings. They also did the welding of the [...]

Steel Rolling Tandem Mill Motor2022-05-16T11:59:45-04:00

20 Foot Germ Twin Screw – Machining Services

Machining Services received a 20 foot Germ Twin Screw one Sunday night with a broken drive end shaft and worn opposite drive end bearing. A Germ Twin Screw is used for moving corn from the third to second floor of the plant. This is where it conveys the germ from the corn from the surge hopper to the fluid bed driver. Then it goes from there to the Franino Press to extract the moisture from the germ. The company this belongs to makes food ingredients. The old shaft of the screw was cut out and a new one manufactured. The opposite [...]

20 Foot Germ Twin Screw – Machining Services2022-01-28T15:39:40-05:00

Out Of Production Lock Nuts

One of Horner’s customers is a major supplier of automotive grade aluminum for major manufacturers of car and truck bodies. After the aluminum passes through a set of rolling mills to reduce the material thickness, the sheet passes through an annealing furnace to reduce material stresses from the rolling process. The annealing furnaces have fans circulating the furnace hot air to evenly distribute the heat to prevent hot spots. This particular fan assembly from one of the annealing furnaces had experienced a bearing failure. The shaft was initially sent to Horner Washington St to evaluate the damage to the main shaft. [...]

Out Of Production Lock Nuts2022-01-26T23:07:37-05:00

Lime and Stone ID Fan

A Lime and Stone Plant called in a panic that one of their Kiln ID Fans has an inboard bearing failure that caused extensive damage to the shaft. The Kiln ID Fan is a key element in this company’s production process, so they needed a quick turnaround. Our team procured the proper shaft material and Machining Services manufactured a new shaft. As a result of Horner’s great vendor relationships, Horner’s purchasing department secured new replacement bearings in record time. The fan was restored and balanced, then assembled with new shaft, bearings, RTDs and the coupling hub. The fan was delivered in [...]

Lime and Stone ID Fan2022-01-26T22:43:22-05:00

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

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

Car Manufacturer Scrap Chute and Shutdown

In April Fan & Fabrication quoted fabricating a scrap chute for an auto manufacturer. This included assisting with removal and installation, design work, fabrication, a rubber sound barrier coating and transportation of the old and new chute. The chute would be fabricated from 1/8” thick AR plate which matched the original design. Angle supports, hanger brackets and replacement flanges would be included. The main body will be covered with a rubber material to offer noise control. The entire project had to be started and completed during the company’s shutdown. This gave Horner just one week to make magic happen. On Saturday [...]

Car Manufacturer Scrap Chute and Shutdown2020-03-06T21:05:54-05:00

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