Custom Metal Gates: Mobile Design, Fabrication, and Install

Gates are the handshake at the property line. They carry the daily loads, set the tone for a home or facility, and signal whether a site is cared for and secure. When they fail, you feel it in minutes: trucks stack up at a loading dock, livestock leave a fence line, On Call Mobile Welding structural welding Plano or a neighborhood entrance looks neglected. Getting a custom metal gate right is equal parts planning, metallurgy, welding process, protection against weather, and smart installation. I’ve designed and installed gates in backyards, at industrial plants, and on ranch roads, and the difference between a gate that just looks good on day one and a gate that still swings true in year ten comes down to a few practical decisions made early.

Where mobile design meets real constraints

Mobile design isn’t a software term here. It means walking the site with a notebook, measuring tape, and camera, then sketching a design that respects slopes, soil conditions, vehicle turning radii, and utility easements. Bringing a welder to the site is valuable, but it’s the site assessment that saves you from rework.

Two examples illustrate the point. A homeowner wanted a clean, horizontal-slat aluminum gate to match modern siding. The driveway pitched 3 inches across a 12-foot span. That doesn’t sound like much, but a rigid, tight-tolerance aluminum panel would eye-sore against the grade, catching leaves and dragging during frost heave. The right call was a slight rake in the frame, paired with adjustable hinges to fine-tune plumb after install. A second case involved an industrial yard where semi-trailers cut the corner of an entry every day. A common picket swing gate would have had a short life. We moved the posts back 2 feet, added a 4-foot wing panel as a sacrificial bumper, and specified a heavier hinge knuckle with a grease fitting. That gate still works after five midwest winters.

A proper mobile design visit includes live checks: the heaviest equipment that will pass through, typical loads at the loading dock, snow plow paths, the swing arc or slide path, and sight lines. People often focus on the gate leaf and forget the fence tie-in and the approach. You can build the prettiest wrought iron fencing and lose the effect when the gate can’t clear a crowned driveway or when a low conduit line blocks post depth.

Material selection: steel, stainless, or aluminum

Material isn’t just a budget question. It determines the fabrication process, the weld procedure, and the maintenance profile.

For most residential gates and ranch entries, carbon steel is still the workhorse. It is affordable, forgiving to weld, and stiff enough that a 12-foot steel leaf with 1.5-inch square tubing rails and pickets will stay true if you brace it correctly. Powder coat over a zinc-rich primer holds up well when you avoid ground contact, and simple weld-on or bolt-on hardware is widely available. For fence welding tie-ins, it mates to existing wrought iron fencing without headaches.

Stainless steel steps in where corrosion can’t be tolerated: coastal salt spray, chemical plants, or food facilities. A brushed 304 stainless frame with TIG welds resists staining, though in chloride-heavy environments 316 stainless is the safer bet. Stainless steel welding does demand discipline. Heat input and distortion control matter, and contamination from carbon steel tools will haunt you with rust specs later. When the budget allows, stainless makes sense for handrails and railings near chlorinated pools, and for industrial swing gates that see washdowns.

Aluminum is the lightweight option. It shines for longer leafs where dead load matters, gate operators with limited torque, and trailers where every pound counts. Welding aluminum requires a welder who is comfortable with the metal’s thermal conductivity and oxide layer. TIG produces attractive, precise welds on visible seams and thin sections. MIG with a spool gun is efficient on thicker members. Aluminum gates need a well-planned frame to resist racking, and hardware selection becomes critical because unprotected fasteners can galvanically corrode when paired with aluminum. Done right, aluminum gates handle weather beautifully, especially with anodizing or a high-quality powder coat.

A quick note on mixed materials. It’s possible to combine a carbon steel hinge post with an aluminum leaf. I’ve done this for a hillside property where the client wanted a light leaf to limit soil movement. It works, but you need isolation pads, proper hardware, and sealants to prevent galvanic issues. If welders or installers skip those small steps, you’ll see white corrosion at the connections within a season.

Choosing the right welding process

The welding process is not a style preference. It impacts the structural integrity, appearance, and cost.

MIG welding is the backbone of most gate fabrication. It is fast, consistent, and versatile on structural tubing and flat bar. With a spray transfer mode in the shop, you can achieve strong, clean beads with minimal spatter. In the field, short-circuit MIG is more common because of power constraints. Pairing a 75/25 gas mix for steel or argon for aluminum on a portable welder gives you decent quality if wind is controlled.

TIG is slower but produces cleaner, more precise welds. For stainless steel welding on visible frames or for delicate scrollwork in decorative gates, TIG wins. It also excels for aluminum welding on thinner profiles. I’ll TIG hinge barrels to stainless posts when the hinge will be at eye level. The heat-affected zone is smaller, the bead is neat, and post-finish work is minimal.

Stick welding still has a place. On structural hinge posts where fit-up isn’t perfect, in windy conditions, or on heavy equipment repairs during an emergency welder callout, SMAW is reliable. For a ranch gate hours from town, I’ve burned 7018 rods off a truck welding rig when the wind made MIG a bad bet. The key is to match the procedure to the material and the condition, then document it.

On larger commercial projects, a certified welder with AWS credentials becomes more than a nicety. If the gate supports a crash-rated barrier or ties into structural components, inspectors will ask for procedure qualifications and welder certs. Even in smaller work, a documented process raises confidence, especially when a property manager has to justify vendor selection.

Structural details that keep gates square

Most gate failures start with a frame that wasn’t stiff enough or a hinge that wasn’t up to the job. The leaf sags, scrapes, and gets band-aided with a wheel. Wheels have their place, but a wheel propping up a tired frame is a symptom.

For rectangular steel gates under 10 feet, 1.5-inch square tubing with a 0.120-inch wall is a practical baseline. Step up to 2-inch square with a 0.188-inch wall for heavier cladding or for industrial duty. Add a diagonal brace from the bottom hinge side to the top latch side to resist sag. In aluminum, bump dimensions roughly one size higher to compensate for lower modulus. On infill, vertical pickets resist racking better than wide horizontal slats, but both can work if you design for it.

Hinge selection should follow the load. A well-made barrel hinge with a 1-inch pin and a grease zerk will carry most residential leaves. For a 14-foot steel gate with a perforated steel sheet, the wind load matters as much as weight. In that case, a pair of heavy pintle hinges or an adjustable ball bearing hinge set prevents binding. When you see a gate that closes perfectly on a calm day and fights you in a crosswind, you’re looking at a gate with too much sail area and not enough hinge capacity.

Posts matter more than frames. A 6x6 steel post set 42 inches deep with a proper bell in concrete will outperform a shallow set 8x8 that moves every winter. In frost zones, extend below frost depth and compact the subgrade. For sliding gates, the track or ground beam needs stable support. A concrete grade beam with embedded steel angle makes a reliable track, and a well-shimmed roller carriage reduces chatter.

Mobile fabrication and on site welding services

Mobile welding is the bridge between design and reality. Shop conditions are ideal, but the field is where measurements meet terrain. A good mobile welder carries more than a portable welder and a grinder. Power options, clamps, magnetic squares, a generator, a stick and MIG setup, and a TIG rig for sensitive work ride on the truck. For stainless, dedicated brushes and clean abrasives prevent contamination. For aluminum in the field, a spool gun and a plan to block the wind matter.

On a retrofit at a distribution center, we added a cantilever gate to an existing fence line by the loading dock. The drawings called for a flush mount, but an underground drain line forced a 6-inch stand-off. Because we had the tools on the truck, we built custom standoffs and modified the latch keeps on the spot, maintaining the structural loads while clearing that obstacle. That agility saves days of downtime on an industrial site.

Truck welding rigs also enable emergency welder calls. A broken hinge plate on a yard gate at 6 a.m. can shut down a lane of traffic and delay deliveries. With a welder who can fabricate a new hinge strap on site, burn in a 7018 root, and cap with MIG for speed, you’re back in service before lunch.

Finishes that survive weather and wear

Bare steel in the rain will show orange streaks within hours. The finish is not decoration, it’s protection. Three common finishes cover most needs.

Powder coating over a zinc-rich primer is the standard for residential and light commercial gates. The zinc primer gives sacrificial protection, the powder provides color and abrasion resistance. The prep matters: degrease, blast to a proper profile, prime, then coat. Avoid welding on a powder-coated frame later, or you burn edges and invite rust. Plan all tabs and brackets before finishing.

Hot-dip galvanizing is rugged. It adds weight and rounds edges, which some clients dislike, but for ranch gates, waterfronts, and industrial sites, the durability pays off. You can leave galvanizing raw with a matte gray look or top-coat with paint. Drill weep holes in closed sections so the molten zinc flows and drains, and be ready for some post-galv straightening as heat can introduce slight warps.

For aluminum and stainless, the finish focus shifts. Aluminum can be anodized or powder coated. Stainless benefits from proper passivation after fabrication, which removes free iron and restores corrosion resistance. Mechanical polishing or a bead-blasted finish hides fingerprints and blends welds. In coastal settings, a gentle rinse during maintenance slows tea staining on stainless, especially for 304.

Gate operators, access control, and power

A gate is increasingly a device in a system. Residential driveways have keypads and app controls. Industrial yards use RFID and timed locks. Choose the operator after you know the gate weight, wind area, cycles per day, and available power.

Swing operators work well for shorter leaves and sites with room to swing. A 24V DC operator with battery backup handles typical residential use, maybe 20 to 40 cycles per day. For heavier gates or frequent use, an AC unit with higher duty cycle avoids overheating. Mount the operator to a stout post or a concrete pad that doesn’t flex, and use a proper linkage to avoid putting side load on the hinges.

Slide operators dominate where space is tight or snow plows run. A cantilever slide avoids ground tracks that pack with gravel and ice. The carriage rollers ride on a tube track welded to the gate. Weight climbs fast on long cantilever gates, so consider aluminum frames to keep operator sizing reasonable.

Safety devices are non-negotiable. Photo eyes, edge sensors, and appropriate signage protect pedestrians and vehicles. UL 325 compliance is not red tape, it’s life safety. When tying into existing access control, plan conduit, junction boxes, and surge protection. For rural sites, a small solar setup can run a low-duty operator, but check shade patterns through the seasons before you commit.

Hardware: small parts, big consequences

Latches, stops, hinges, and closers fail more often than frames. The wrong latch on a slope becomes a daily irritation. A slam stop made from thin angle tears off within a month on a busy gate.

On a high-cycle pedestrian gate at a warehouse, we switched from a light gravity latch to a stainless, self-latching keep with an electric strike. It paired with a closer tuned for a soft catch. That small change cut service calls dramatically. For vehicle gates, I like a mechanical positive stop at both open and closed positions. It takes load off the operator and the hinges during wind gusts. Use stainless fasteners where possible and isolate dissimilar metals with nylon washers or gaskets to prevent corrosion.

When welding on hinge barrels, keep heat minimal near the pin and bushing. I often clamp a piece of aluminum as a heat sink next to the weld area. On adjustable hinges, lock nuts and thread locker are cheap insurance against vibration.

Dealing with grade, frost, and movement

Ground moves. Water flows where you wish it wouldn’t. A gate that ignores geology becomes a maintenance project. On slopes, consider a rising hinge that lifts the leaf as it opens, or switch to a slide gate to avoid grinding the pavement. For clay soils that swell, deepen the post embedment and shape the concrete to shed water away from the post.

In frost zones, an improperly set post will heave and throw the latch off by half an inch every winter. Extending below frost line and using clean, compacted gravel at the base of the hole reduces movement. In sandy soils, the problem is different: posts can settle. Wider footings or soil stabilization helps. I’ve also used screw piles where excavation is limited by underground utilities. They provide immediate load capacity and minimize spoil, which is helpful around a loading dock cluttered with buried lines.

Wind can be as destructive as soil. A solid infill panel looks sleek, but it acts like a sail. Perforated sheet, lattice, or spaced pickets relieve pressure. If you must use solid infill for privacy, step up hinge and post sizes and add robust stops to protect the operator.

Repair and retrofit strategies

Not every project starts from scratch. I see plenty of pipe repair on farm gates, hinge strap replacements on school yards, and structural fixes after a truck clips a post. A careful repair beats a quick patch. If a post bends at grade, replacing or sleeving the post is better than cutting and plating the bent area. For cracked welds at the latch side, inspect for racking. Welding over a crack without addressing the frame geometry is a short-lived fix.

On wrought iron fencing tie-ins, old metal often contains mill scale and paint layers. Grind to clean metal, preheat in cold weather, and stitch weld to avoid pulling the fence out of line. Where rust has thinned material, replace sections rather than chasing pinholes.

For industrial sites, downtime costs money. I keep a small stock of common components on the truck: hinge barrels in several sizes, latch keeps, roller carriages for slide gates, and lengths of 2-inch square tubing. With those, on site welding services can take a damaged gate from inoperable to functional in one visit, then return for a more thorough rebuild after hours.

A word on permits, codes, and inspections

Authorities care most about life safety and public right of way. In some municipalities, any gate that encroaches into a sidewalk or a fire lane needs approvals. Pool gates have strict latch height and self-closing rules. Commercial sites may require stamped drawings for structural posts or crash-rated barriers. Even where a permit isn’t required, following recognized standards and using a certified welder for structural connections reduces risk.

Keep documentation in order. If your gate ties to a building or to a public fence line, inspectors may ask for weld procedure specifications and material certs. It’s not overkill. When a hinge plate tears and a 400-pound leaf falls, lawyers will want to know who decided what and why.

Workflow that keeps projects on track

A clean workflow makes the difference between site-ready and shop-bound. The pattern I’ve settled into looks like this:

• Site visit and load assessment, including grade, utilities, clearances, and traffic patterns.
• Sketch and material selection, with a quick check on finish lead times and operator compatibility.
• Shop fabrication with trial fit on a jig, then finish application scheduled to land right before install.
• Mobile install with on site welding services for final alignment, latch tuning, and hardware anchoring.
• Commissioning of operators and access control, with cycle testing, safety device checks, and owner walk-through.

That sequence avoids the common trap of finishing too early, then burning your coating to add a bracket, or discovering at the curb that your beautiful flat gate meets a wavy driveway.

Cost drivers and where to invest

Budgets vary, but certain choices pay off. Spend money on posts, hinges, and finish. A heavier post and hinge set costs a few hundred more than light-duty hardware and saves thousands in callbacks. Don’t cheap out on powder coat prep or galvanizing. For operators, size for worst case, not average. If your gate lives near a windy corner, that extra torque is the difference between a gate that closes every time and an operator that faults and leaves the site unsecured.

Material choice affects labor. Aluminum hardware and isolation steps add time. Stainless TIG work takes longer than MIG on steel. If a client wants the look of stainless without the cost, a steel frame with a fine powder coat and stainless infill accents can hit the mark at a lower price.

Case sketches from the field

A food processing plant needed a stainless swing gate for a washdown corridor. The environment was harsh: hot water, caustic cleaners, and frequent cycles. We chose 316 stainless for the frame and hinges, TIG welded the joints, passivated the assembly, and used a nylon-bushed hinge set to avoid crevice corrosion. Fasteners were all stainless with anti-seize. After two years, inspection showed no pitting and only light tea staining that wiped clean.

On a rural property, a heavy-duty pipe gate kept sagging every spring. The soil swelled and the shallow post turned in the ground. We pulled the post, drilled deeper below frost, belled the footing, and added a diagonal brace in the leaf. A simple greaseable hinge replaced the old strap. That gate has survived three freeze-thaw seasons without adjustment.

At a busy warehouse, a slide gate scraped and stalled. The track had settled and trapped gravel. We replaced the ground track with a cantilever setup, adding a concrete grade beam and new roller carriages sized for the heavier frame. The operator no longer fought debris, and snow removal got easier. It was a bigger upfront cost, but it stopped the monthly service calls that made their maintenance manager dread winter.

Safety culture on install day

Gate installs mix welding, grinding, heavy lifting, and sometimes live traffic. A short safety talk prevents injuries that ruin schedules and lives. Block off swing arcs, set cones to separate the work zone from vehicles, and keep a fire watch during welding. Wet grass and powder coat dust burn faster than you expect. For truck welding near a fueling area, confirm hot work permits. These are small disciplines that distinguish professionals from hobbyists.

Maintenance that extends service life

Even the best gate needs attention. A yearly check on hinge bolts, a shot of grease on bearings, a look at powder coat chips, and a rinse for salt exposure extend life. For operators, battery backups need replacement every few years, photo eyes need cleaning, and limit switches drift. Build maintenance into the handover. Leave the owner with a simple schedule and the supplier’s contact for parts.

For industrial gates, consider a quarterly walk with the facilities team. You catch cracked welds around a loading dock early, spot ruts forming near the posts, and schedule repairs before a failure halts operations. That level of service separates a welder who builds and leaves from a partner who keeps equipment working.

When speed matters: emergency response

Steel fails at inconvenient times. A forklift bends a latch post at 5 a.m., or a storm rips a fence and leaves the yard open. An emergency welder with a well-stocked truck can stabilize the situation. The first goal is secure the site. That might mean welding a temporary brace, chaining a leaf closed, or installing a temporary panel. The second goal is plan the permanent fix. Document the damage, measure for new components, and schedule the follow-up. Clients remember who shows up fast with competence when stress is high.

The craft in the details

A gate is more than a rectangle on hinges. It is an engineered object that lives outdoors, moves thousands of times, and endures abuse. Good outcomes come from respecting the physical realities: weight, wind, water, soil, and cyclic loads. They also come from experienced hands choosing when to MIG for speed, when to TIG for precision, when to galvanize, and when to keep it simple.

Custom metal gates, whether steel, stainless, or aluminum, benefit from the mobility of a truck welding setup, the precision of shop jigs, and the judgment of a certified welder when the structure demands it. Couple that with practical hardware, thoughtful finishes, and honest maintenance, and your gate won’t just look right on day one. It will swing true, lock clean, and keep working long after trends change and paint fades.

On Call Mobile Welding

917 J Pl Suite 2, Plano, TX 75074

(469) 750-3803