thermal spray

University Pump Project

A prominent public university recently faced the challenge of maintaining around 30 critical pumps across its campus, including heat and chiller pumps, sewage pumps, storm drain pumps, inline booster pumps, and condensate pumps. With no in-house maintenance department due to a shortage of skilled trade workers, the university turned to Horner for a comprehensive solution. The project involved refurbishing, replacing, and repairing various pumps, with some also requiring new motors. Horner Pump Repair, Horner Terre Haute, and Indianapolis Field Service collaborated closely to deliver outstanding results. The project was led by Kenzie Mace, Sales Rep, and Travis Brown from Terre Haute, [...]

University Pump Project2025-07-24T10:43:11-04:00

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

Horner Electro-Mechanical Diagnostic Group – Coal Fired Power Plant Vertical Motor

At Horner Industrial Group, we take pride in our commitment to excellence and preventative maintenance solutions. Recently, our EMDS department had a significant impact on the operations of a coal-fired power plant, showcasing the vital role of hands-on data collection and analysis in preventing potential disasters. Our client, a coal-fired power plant, relies heavily on rotating equipment to maintain its operations. Every month, our vibration technician Joe Roseberry, performs vibration data collection and analysis on all rotating equipment at the plant. One critical piece of equipment under Joe’s watchful eye is an agitator, which plays a crucial role in an environmental [...]

Horner Electro-Mechanical Diagnostic Group – Coal Fired Power Plant Vertical Motor2025-01-15T11:05:08-05:00

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

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

Steel Mill Cooling Tower Fan Support

            Multiple Horner Industrial Divisions worked together to secure a fan on a cooling tower for the Steel Mill customer. Air conditioning equipment and industrial processes can generate heat in the form of tons of hot water that needs to be cooled down. That’s where an industrial cooling tower comes in. Overheated water flows through the cooling tower where it’s recirculated and exposed to cool, dry air. Heat leaves the recirculating cooling tower water through evaporation. This is called evaporative cooling. The colder water then reenters the air conditioning equipment or process to cool that equipment [...]

Steel Mill Cooling Tower Fan Support2024-02-28T10:27:27-05:00

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

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

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

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