machining services

Cement Fan Repair

Horner completed a challenging repair and installation project for a cement manufacturer,showcasing our team’s dedication and expertise in the face of extreme conditions. The project centered on repairing a 72” fan and shaft assembly essential to the operation of a new 1250HP Toshiba Medium Voltage Drive. This installation marked the second phase of a four-year initiative and required precise coordination and execution during a tight 10-day shutdown window. Our machining services team performed comprehensive repairs to the fan/shaft assembly, which included: • Sandblasting the fan clean • Installing a new hub and shaft • Machining the hub face • Conducting ultrasonic [...]

Cement Fan Repair2026-04-15T11:57:10-04:00

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

When Buying New Is Too Much – Repair

Horner recently achieved a remarkable success story with a major steel mill. They make specialty metals for the aircraft and aerospace industries including rolled steel, bars, ingots, and wire. Initially poised to purchase two new fan units for their exhaust system in their Finish/Sizing Mill, they hesitated due to concerns over pricing and lead time. Sensing an opportunity for collaboration, I proposed the idea of reconditioning the units instead. Working closely with Horner Fan & Fabrication, we meticulously crafted a competitive quote, addressing the client’s concerns head-on. Despite initial reservations, we assured them of a swift turnaround time of 3 to [...]

When Buying New Is Too Much – Repair2025-01-15T12:21:27-05:00

Starch Mixing Logs

          An ingredient manufacturer had damaged 20 foot mixing logs that mixed up starch. The customer gave us a tight schedule of 5 days to remove the damaged gears, coupling, bearings, and all bent and broken paddles. Basically receive it Monday and return them Friday! Horner Machining Services worked with Fan and Fabrication to get the job done. Machining straightened the shafts and fixed the gears and bearings. Fan and Fabrication laser cut and installed 64 new stainless steel paddles on the mixing logs. It took both divisions and three shifts through the week to make the [...]

Starch Mixing Logs2024-02-28T10:35:03-05:00

Terre Haute Industrial Equipment Repair Working The Weekend

Terre Haute has been busy with a lot of work from great customers. Recently a plastics recycling customer called about high vibration on a dryer auger. This customer recycles the plastic processing it into industrial resins that are used to make plastic bags. The stainless-steel auger is used to convey plastic pellets during the washing process, prior to drying and packaging. Due to high vibration the auger was pulled and sent to the Terre Haute shop for repair. Jeremy Brown, machinist, dynamically balanced the auger and sent it back the recycling facility to be put back into production. Another project that [...]

Terre Haute Industrial Equipment Repair Working The Weekend2023-06-16T13:28:51-04:00

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

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