manual machining

Rubber Plant Motor Failure

A 400HP WEG motor on the hydraulic power unit of a plant’s main mixer failed due to a catastrophic drive-end (DE) bearing issue. The bearing failure generated sparks and halted the production of raw rubber critical for automotive products. With the backup mixer already out of service—its old DC motor awaiting replacement in February 2025—production came to a complete standstill. Upon inspection, it was clear the inner race of the failed bearing had welded itself to the motor shaft. The motor was promptly sent to Horner Machining Services (HMS) division for shaft repair. Once disassembled at Washington Street, HMS discovered deep [...]

Rubber Plant Motor Failure2026-04-15T12:07:14-04:00

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

Power Plant Shut Down Work

We all know that shutdown work is critical to all customers, how- ever, when we are working for a powerplant the stakes are even higher. Bert Serak sold a lot of shutdown work for a powerplant located in southeastern Ohio. The first job was a 1000 HP motor that had to be rebuilt and returned in 5 days. This motor looked like a UFO when it was lifted by a crane to the rooftop of the plant. The next opportunity was to rebuild a dozen fans and drive motors in 5 days. We sent two trucks to pickup the fans and [...]

Power Plant Shut Down Work2024-11-15T12:56:34-05:00

Pinion Gear for Crusher

In the latest triumph of efficient problem-solving, our team at Horner Machining Services swiftly came to the rescue when an aggregate plant faced a crusher system outage due to a damaged pinion gear for their primary crusher. Understanding the urgency, we executed a super quick turnaround, minimizing downtime and financial losses for the plant. The significance of pinion gears and racks in the mechanical world cannot be overstated; their toothed design along flat surfaces con- verts rotational motion into linear motion, forming an integral part of traditional drivetrains. Fun fact: the first commercially successful steam locomotive featured a pinion gearbox! At [...]

Pinion Gear for Crusher2024-11-15T12:58:05-05:00

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

Vibration Issue on Forced Draft Fan

A 100 year old steam plant was having a long standing vibration issue that they could not correct. Our EMDS department determined the likely issue was the hub to shaft fit. Horner Machining Services did most of the work on this fan including: • Remove old bearing, couplings, and louvers • Press old shaft out of the fan • Sand blast the fan and louvers clean • steam clean coupling • set up new shaft and check for straightness, then install • Dynamic Balance • Paint and reinstall the original coupling Field Service did the on-site work for removal, installation, and [...]

Vibration Issue on Forced Draft Fan2022-01-26T23:26:33-05:00

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

Aluminum Plant Outage

In June of 2017 an Aluminum plant contacted us to begin the early planning stages of their outage which was scheduled for January 2018. The customer was about to undertake the most involved outage on their primary mill and wanted Horner’s exclusive involvement. The outage was a success despite the very large scale and daunting tasks assigned. All work was coordinated by Ralph Coonce of field service. If you’ve ever seen Ralph in action during an outage I don’t have to explain that he doesn’t just show up. He’s elbow deep in the actual work turning wrenches or any another task [...]

Aluminum Plant Outage2019-09-09T17:28:00-04:00

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