Heavy Rolling Gate at a Brewery in El Paso, Texas

Comunello 6" V-Groove Galvanized Wheel and BFT ICARO FAST Gate Operator

When Site Conditions Change, Smart Hardware Keeps the Project Moving

Case Study

El Paso, Texas

Completed Jan 2022

Brian Howard, Black Knuckle Metals

At DeadBeach Brewery, the gate design needed to balance function with atmosphere. Serving as both a perimeter solution and a visual extension of the brewery’s industrial character, the sliding gate had to operate smoothly in a high-use outdoor environment—without calling attention to the mechanics behind it.

The brewery’s production-side gates open and close multiple times a day, demanding reliability first and foremost. The goal wasn’t to make the hardware a focal point, but to ensure it performed consistently in a demanding, real-world setting.

Designed and custom-fabricated by Brian Howard of Black Knuckle Metals , the original concept prioritized clean movement, long spans, and long-term durability—keeping the hardware working quietly in the background while letting the architecture lead.

When Site Conditions Change, Smart Hardware Keeps the Project Moving

The Challenge

Working with Black Knuckle Metals, AIDI supported the fabrication and installation of a pair of custom sliding gates for DeadBeach Brewery. Brian’s original design called for a Comunello DuraGates® cantilever system, supporting two 30-foot-long, 12-foot-high custom gates engineered for smooth, track-free operation.

During construction, however, site conditions changed.

An outside contractor poured the concrete and installed the fence and post elements without following the approved plans—expanding the opening by five feet on one side and eight feet on the other. With the foundation already in place, the cantilever configuration was no longer viable without major rework.

To accommodate the widened opening, Brian was forced to extend the gate leaves to 35 feet and 38 feet, adding hundreds of pounds of additional weight. Given the increased load—and the fact that these gates serve the active production side of the brewery, cycling open and closed multiple times per day—the system needed to be re-evaluated quickly.

The Solution

Rather than reworking the entire design, Black Knuckle Metals transitioned the system to a V-groove configuration using AIDI components that could adapt to the existing conditions while maintaining smooth, dependable operation.

The revised solution centered on Comunello’s 6" V-Groove Wheel system, selected for its load capacity, durability, and compatibility with real-world installs:

  • 6" galvanized V-groove wheel
  • Single bearing design
  • 1" wide wheel profile
  • 639 lb load capacity per wheel
  • M16 x 70mm wheel pin

To complete the system, the gate was paired with the BFT ICARO FAST Gate Operator, an electromechanical automation solution designed for rack-driven sliding gates up to 1,300 lbs. The combination delivered consistent movement, reliable automation, and long-term serviceability—without requiring further site reconstruction.

“This was my first time ordering from AIDI, and they helped me at every step,” Brian says. “They were amazing to deal with—understanding, responsive, and willing to work with me to find the right solution. They even allowed me to exchange the system so the project could move forward.” – Brian Howard, Black Knuckle Metals

The Result

By pivoting from cantilever to V-groove, Black Knuckle Metals kept the project on track and avoided costly delays or rework. AIDI’s components allowed the design intent to stay intact while accommodating the realities of the site.

The finished gate delivers:

  • Smooth, stable sliding performance
  • Durable, galvanized hardware built for outdoor use
  • Automation matched to gate weight and duty cycle
  • A clean, professional install despite last-minute changes

Completed in 2022, the gates continue to perform as intended in a demanding production environment.

“I’m proud to say I’ve never received a single phone call that something was wrong.” – Brian Howard

 

The Takeaway

This project highlights what happens when experienced fabricators are paired with flexible, field-tested components. Not every job site goes according to plan—but having the right hardware options makes adaptation possible.

For Black Knuckle Metals, Comunello’s V-groove and BFT’s automation solutions turned a potential setback into a successful install—proving that smart hardware choices can keep even imperfect projects moving forward.

Hardware: Comunello 6" V-Groove Galvanized Wheel and BFT ICARO FAST Gate Operator
Fabricator: Brian Howard, Black Knuckle Metals
Client: DeadBeach Brewery
Location: El Paso, Texas

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