Heavy industrial equipment is built to take punishment.

But nothing lasts forever.

Years of abrasion, impact, heavy loading, continuous operation, and harsh environments eventually take their toll on steel, mechanical components, wear areas, bores, shafts, pins, structural members, and mounting points.

When the equipment still has significant value, replacing it may not be the only option.

Electric Machine & Fab provides heavy equipment rebuilding and industrial equipment restoration for mining, construction, material handling, processing, and other severe-duty applications.

With capabilities in heavy welding, industrial fabrication, machining, plate cutting, reverse engineering, custom replacement parts, assembly, and finishing, EMF can take on rebuild projects that require much more than a simple repair.

Rebuild Instead of Replace

A piece of industrial equipment can look worn beyond recognition and still have a foundation worth saving.

That is what a proper rebuild evaluates.

Instead of focusing only on the visible damage, EMF can assess the component or assembly as a whole and determine what can reasonably be restored.

Depending on the project, a rebuild may involve:

• Removing damaged or worn material
• Structural repair
• Heavy welding
• Replacement steel
• Reinforcement
• Bore restoration
• Shaft and pin repair
• New bushings or sleeves
• Custom replacement components
• Machining
• Fabrication
• Wear-area rebuilding
• Reassembly
• Finishing and industrial painting

The goal is not to make worn equipment look better.

The goal is to return it to useful service.

Mining Equipment Rebuilds

Mining equipment is some of the most severely used machinery in industry.

Underground and surface equipment is exposed to:

• Abrasive material
• Heavy loading
• Impact
• Structural stress
• Continuous wear
• Harsh operating environments

EMF has extensive capabilities suited to mining equipment rebuild projects.

Work can involve:

• Longwall mining components
• Buckets
• Scoops
• Structural assemblies
• Equipment frames
• Wear components
• Mechanical interfaces
• Shafts
• Pins
• Bores
• Replacement sections
• Custom fabricated parts

A mining rebuild may require several processes before the component is ready to return to service.

Explore Mining Equipment Repair & Rebuilding →

Longwall Mining Component Rebuilding

Longwall mining equipment contains substantial components that operate under extreme loads and demanding underground conditions.

Over time, these components can experience:

• Severe wear
• Structural cracking
• Material loss
• Distortion
• Worn mounting areas
• Damaged mechanical interfaces

EMF can support longwall mining component repair and rebuilding using fabrication, heavy welding, machining, replacement steel, and custom component manufacturing.

Depending on the condition of the component, work may involve:

• Removing worn areas
• Rebuilding structural sections
• Welding replacement material
• Machining repaired areas
• Restoring mechanical interfaces
• Replacing wear components
• Manufacturing unavailable parts
• Finishing and painting

The focus is on the repairable components and assemblies that make up these systems.

Bucket & Scoop Rebuilding

Buckets and scoops take direct punishment from the material they move.

Coal.

Stone.

Aggregate.

Soil.

Rock.

Bulk material.

Over time, abrasion and impact can remove a surprising amount of steel.

EMF can rebuild heavy buckets and scoops through a combination of:

• Worn steel removal
• Replacement plate installation
• Structural repair
• Heavy welding
• Resurfacing
• Reinforcement
• Wear-area restoration
• Machining
• Replacement components
• Finishing and painting

A heavily worn bucket does not automatically mean a replacement bucket is required.

If the primary structure remains usable, rebuilding may be worth evaluating.

Structural Equipment Rebuilding

Heavy industrial equipment often fails structurally before it becomes useless mechanically.

Cracks develop.

Frames wear.

Mounting points become damaged.

Steel distorts.

Sections lose material.

A substantial structural repair may require more than simply welding over the visible crack.

EMF can evaluate the surrounding structure and rebuild damaged areas using:

• Heavy plate
• Replacement steel sections
• Industrial welding
• Reinforcement
• Custom fabrication
• Machining
• Replacement components

The objective is to address the damaged area as part of the larger structure.

Heavy Welding for Equipment Rebuilds

Heavy equipment rebuilding depends on serious welding capabilities.

EMF provides industrial welding for:

• Mining equipment
• Earthmoving equipment
• Structural components
• Equipment frames
• Heavy plate
• Repair sections
• Reinforcement
• Custom fabricated assemblies
• Wear components

Welding is often only one step in the rebuild.

Once the structural work is complete, the project may move into machining, assembly, component installation, and finishing.

Explore Industrial Fabrication & Welding →

Industrial Machining During Rebuilds

A rebuild can involve massive steel and still require precision mechanical work.

Pins must fit.

Bores must align.

Shafts need proper surfaces.

Bearing fits matter.

Mechanical interfaces need to function correctly.

EMF's industrial machining capabilities can support rebuild work involving:

• Pins
• Shafts
• Bushings
• Sleeves
• Bores
• Journals
• Hubs
• Bearing fits
• Mounting surfaces
• Mechanical interfaces
• Custom replacement components

This ability to combine structural rebuilding with precision machining is one of the key advantages of EMF's integrated capabilities.

Explore Industrial Machining & CNC Machining →

Pin & Bore Restoration

Heavy equipment frequently concentrates enormous forces through pins, bores, bushings, and pivot points.

As those areas wear, looseness increases.

That can accelerate damage throughout the equipment.

Depending on the component, EMF can evaluate worn pin-and-bore areas and determine whether they can be:

• Machined
• Rebuilt
• Sleeved
• Re-bushed
• Restored with replacement components
• Modified as part of a larger repair

If the existing pin or related component is beyond use, EMF may also be able to manufacture a replacement.

Heavy Plate Replacement

Severe wear sometimes removes too much material for a localized repair.

Entire sections of steel may need to be replaced.

EMF's heavy fabrication and plate-processing capabilities allow replacement sections to be cut and fabricated for substantial rebuild projects.

At our Sidney, Kentucky facility, EMF operates a large-format Messer CNC cutting system with a:

10-Foot × 30-Foot Cutting Table

For appropriate materials and applications, EMF can process heavy plate in the 8- to 10-inch thickness range.

That capability can support rebuilds requiring:

• Structural replacement sections
• Wear plates
• Heavy repair pieces
• Equipment bases
• Mounting plates
• Reinforcement
• Custom fabricated components

Explore Large-Format CNC Plasma & Plate Cutting →

Custom Replacement Components

A rebuild can come to a halt because of one missing part.

And with older equipment, that part may no longer be available.

EMF can manufacture custom replacement components using:

• Industrial machining
• CNC machining
• Fabrication
• Plate cutting
• Reverse engineering

Projects can begin from:

• Existing drawings
• Specifications
• Existing parts
• Worn samples
• Measurements
• Equipment information

This can be especially valuable when working on older, specialized, or modified industrial equipment.

Explore Parts Manufacturing & Replacement Parts →

Reverse Engineering During Equipment Rebuilds

Older equipment often arrives without complete documentation.

The OEM may no longer exist.

Drawings may be missing.

The equipment may have been modified years ago.

In those cases, the damaged component itself can become part of the information needed to move forward.

EMF can use engineering, analysis, and reverse engineering to help determine the requirements for replacement or repair components.

From there, the project can move directly into machining, fabrication, or custom manufacturing.

Explore Engineering, Analysis & Reverse Engineering →

Equipment Modification During a Rebuild

A rebuild can also be an opportunity to address problems that have developed over years of operation.

In some cases, the original configuration may no longer make sense.

A replacement component may not fit exactly.

A mounting arrangement may need to change.

A worn area may benefit from reinforcement.

A custom adapter may be required.

EMF can combine engineering, machining, fabrication, and equipment repair capabilities to support practical modifications during a rebuild.

Explore Equipment Retrofitting & Modernization →

From Worn Component to Finished Rebuild

A substantial rebuild may move through several stages.

Inspection → Disassembly → Damage Removal → Plate Cutting → Fabrication → Welding → Machining → Replacement Components → Assembly → Finishing

Not every project requires every stage.

But having these capabilities available within one company allows EMF to handle more of the complete rebuild process.

Before & After: Where the Work Speaks for Itself

Equipment rebuilds are among the most visual examples of what EMF can do.

A component may arrive:

• Worn nearly through
• Cracked
• Bent
• Missing steel
• Mechanically loose
• Covered in years of industrial wear

Then the rebuilding process begins.

Damaged areas are removed.

Steel is replaced.

Critical surfaces are restored.

Components are machined.

New parts are installed.

The equipment is reassembled and finished.

Those before-and-after transformations are exactly why EMF's rebuild projects deserve to be seen.

Explore the Facility & Equipment Gallery →

Rebuilds for Heavy Construction & Earthmoving

The same capabilities used in mining equipment apply naturally to heavy construction and earthmoving machinery.

EMF can support rebuild projects involving:

• Buckets
• Scoops
• Structural assemblies
• Frames
• Pins
• Bores
• Shafts
• Wear components
• Mounting points
• Heavy fabricated sections

Equipment that moves stone, soil, coal, aggregate, and other abrasive material experiences many of the same problems regardless of the industry.

Explore Heavy Construction & Earthmoving →

Industrial Equipment Rebuilding Beyond Mining

EMF's rebuild capabilities can also support equipment used in:

• Industrial Manufacturing
• Processing Facilities
• Utilities & Power Generation
• Heavy Construction
• Aggregate Operations
• Material Handling
• Municipal & Infrastructure
• Other Heavy Industrial Applications

The machine may be completely different.

The repair problems often aren't.

Wear.

Damage.

Structural failure.

Obsolete components.

Mechanical deterioration.

Those are problems EMF is built to solve.

Sidney, Kentucky: A Center for Heavy Rebuild Work

EMF's Sidney, Kentucky facility is a major center for heavy equipment and component rebuilding.

15400 Bent Mountain Road
Sidney, KY 41564

Capabilities include:

• Heavy industrial fabrication
• Heavy welding
• Mining equipment rebuilding
• Heavy equipment repair
• Industrial machining
• CNC machining
• Large-format CNC plate cutting
• Custom parts manufacturing
• Structural repair
• Industrial finishing

The combination allows large equipment to move through multiple repair processes without sending every stage to a different shop.

Explore Sidney, Kentucky →

Backed by Williamson

Heavy equipment projects can also draw on EMF's Williamson, West Virginia facility.

Williamson brings additional strength in:

• Industrial machining
• Large industrial electric motor repair
• Electromechanical repair
• Mechanical component restoration
• Power transmission repair support

Together, the two facilities allow EMF to address both the structural and mechanical sides of industrial equipment problems.

Explore Williamson, West Virginia →

Repair It or Replace It?

Not every component should be rebuilt.

Sometimes replacement is the right answer.

But when the equipment is substantial, specialized, expensive, or difficult to replace, rebuilding deserves serious consideration.

EMF can help evaluate whether it makes sense to:

Repair it.
Address localized damage.

Rebuild it.
Restore multiple worn or damaged areas.

Reproduce it.
Manufacture a replacement component.

Modify it.
Adapt the equipment to meet current needs.

The right answer depends on the equipment, its condition, and the project.

Bring Us the Worn-Out Stuff.

The bucket with half its steel gone.

The frame with the ugly crack.

The oversized bore.

The worn pin.

The mining component that has seen better decades.

The obsolete assembly nobody wants to touch.

That's Exactly the Kind of Project We Want to See.

Electric Machine & Fab combines heavy welding, fabrication, machining, plate cutting, reverse engineering, replacement-part manufacturing, and equipment rebuilding to take on industrial projects that require more than a quick patch.

Send us photos.

Bring us the component.

Tell us what failed.

We'll help determine whether it can be put back to work.

REQUEST A QUOTE