Can the MagTrack be used for offshore structure maintenance?

Yes, the MagTrack can absolutely be used for offshore structure maintenance. As a magnetic crawler designed for steel surfaces, it adheres firmly to hulls, platforms, and structural steelwork in marine and offshore environments. The MagTrack Mini is even available as a certified ATEX Zone 2 unit, making it suitable for use in potentially explosive atmospheres common on offshore oil and gas installations.

Whether you are maintaining a fixed platform, a floating production unit, or a vessel operating in harsh sea conditions, MagTrack offers a robotic alternative to manual cleaning that improves both safety and surface preparation quality. The sections below address the most common questions maintenance engineers and field technicians ask before deploying MagTrack in an offshore setting.

What types of offshore structures can MagTrack work on?

MagTrack is designed to work on flat and slightly curved steel surfaces, which covers the majority of structural steelwork found on offshore installations. This includes fixed offshore platforms, floating production, storage, and offloading (FPSO) vessels, jack-up rigs, semi-submersibles, and the steel hulls and cargo holds of support vessels. Any steel surface that allows magnetic adhesion is a candidate for MagTrack deployment.

The modular design of the system means the right tool can be matched to the geometry of the structure. The standard Blast Can is ideal for flat deck plating and structural panels, while the Curved Blast Can extends capability to surfaces with a radius of up to 3 meters “approximately 9.8 feet”, which is well suited to the curved contours of ship hulls, storage tanks, and cylindrical structural members.

The MagTrack Mini deserves particular mention in the offshore context. Its compact, lightweight build makes it straightforward to transport to remote locations, and its narrow profile allows it to access confined areas such as the interior of cargo holds or tight structural bays on a rig. The 2025 model improvements to the drivetrain and vacuum seal make it even more practical for demanding offshore conditions.

How does MagTrack maintain adhesion on offshore steel surfaces?

MagTrack maintains adhesion through a system of height-adjustable magnets integrated into the carrier frame. These magnets create a strong, continuous hold against ferromagnetic steel surfaces, allowing the crawler to operate on vertical walls, overhead sections, and inclined plating without the risk of falling or losing contact. The magnetic force is calibrated to balance holding strength with manageable driving resistance.

On the MagTrack Mini, additional omni-wheel rear support with extra height-adjustable magnets provides supplementary adhesion, while two omni-wheels at the front support the blast can and allow smooth directional changes. This configuration keeps the crawler stable even when the blast can is pressurised and the vacuum unit is drawing debris from the surface.

One practical consideration for offshore use is surface condition. Heavy marine fouling, thick coating layers, or severe corrosion can affect the consistency of magnetic contact. In most maintenance scenarios, however, the crawler is deployed precisely to address these conditions, and the adhesion system is robust enough to handle the variable surface quality typically encountered on ageing offshore steelwork.

What surface preparation standards can MagTrack achieve offshore?

MagTrack can achieve high-grade surface preparation results comparable to Sa 2.5 and Sa 3 cleanliness levels when used with the appropriate modular tools. The high-pressure water jetting tools operate across a range from 500 to 3,000 bar “approximately 7,250 to 43,500 PSI”, giving operators the flexibility to select the pressure level that matches the coating removal or cleaning requirement at hand.

The closed-circuit Blast Can and Curved Blast Can tools perform waterblasting while simultaneously collecting water and debris through a connected vacuum unit. This means no contamination is released onto the surrounding structure or into the sea, which is a critical requirement when working on offshore installations subject to environmental regulations. The result is a clean, dry surface that is ready for coating or inspection immediately after the pass.

For applications where surface roughness needs to be established before coating, the ReCycleBlaster attachment enables closed-circuit abrasive blasting. This vacuum blasting approach recycles the abrasive material, reduces the release of harmful airborne particles, and leaves a prepared profile without contaminating the work area. On an offshore platform where housekeeping and environmental compliance are non-negotiable, this is a significant operational advantage.

The Sandblaster Swing Arm is available for open abrasive blasting where collection of debris is not required, and it can be configured with one, two, or three abrasive nozzles depending on the production rate needed. Height, angle, and pitch are all adjustable, allowing precise overlap on large structural areas.

How does MagTrack improve safety during offshore maintenance?

MagTrack improves offshore maintenance safety by removing operators from the most hazardous positions in a high-pressure cleaning or surface preparation operation. Instead of personnel working at height, over water, or in confined spaces while handling high-pressure equipment directly, a remote-controlled crawler takes on the physical cleaning task while the operator remains at a safe distance.

High-pressure water jetting at pressures between 500 and 3,000 bar “approximately 7,250 to 43,500 PSI” carries a serious injury risk if equipment is mishandled or malfunctions. Industry bodies including SIR (Netherlands), EWJI (Europe), WJA (UK), WJTA (USA), and DIRV (Germany) all publish guidance on safe working practices for water jetting operations, and a recurring theme across all of them is the value of reducing direct operator exposure to the jetting zone. MagTrack directly addresses this by keeping the high-pressure nozzle on the robot rather than in a person’s hands.

The ATEX Zone 2 certification available for the MagTrack Mini is particularly relevant on offshore oil and gas installations, where flammable gas or vapour may be present. Operating electrically driven equipment in such environments without appropriate certification is a serious safety and regulatory risk. The certified ATEX version removes that concern and allows the crawler to be deployed in areas that would otherwise be off-limits to non-rated equipment.

The closed waterblasting configuration also contributes to a safer work environment by containing water and debris within the vacuum system. This prevents slippery surfaces from forming around the work area and reduces the risk of secondary incidents caused by wet decking or airborne debris.

What are the operational limitations of MagTrack in offshore environments?

MagTrack has several operational boundaries that maintenance teams should factor into their planning before deploying the system offshore. Understanding these limitations upfront allows for realistic scheduling and avoids unexpected delays during critical maintenance windows.

The most fundamental limitation is surface compatibility. MagTrack requires a ferromagnetic steel substrate to function. Non-magnetic materials such as aluminium superstructures, GRP panels, or stainless steel components cannot support magnetic adhesion, so those areas must be addressed using alternative methods. On most offshore steel structures this is not a major constraint, but it is worth mapping out the full scope of work before mobilisation.

Surface geometry is a second consideration. The standard carrier is designed for flat and slightly curved surfaces. Highly irregular geometry, sharp internal corners, or complex three-dimensional structures such as lattice bracings and tubular joints may not be accessible to the crawler. The Curved Blast Can extends reach to surfaces with a radius down to 3 meters “approximately 9.8 feet”, but tighter radii or complex intersections will require supplementary manual work.

Weather and sea state also affect offshore deployment. High winds and vessel motion on floating structures can influence the stability of the crawler, particularly on vertical or overhead sections. Operational windows need to be assessed against prevailing conditions, and deployment planning should include contingency for weather-related delays.

Finally, the MagTrack system requires a high-pressure water supply and, for vacuum blasting configurations, a vacuum unit. These support systems need to be mobilised alongside the crawler, which adds to the equipment footprint and logistics complexity on a congested offshore deck.

How does MagTrack compare to traditional offshore cleaning methods?

Compared to traditional manual water jetting and abrasive blasting, MagTrack offers meaningful advantages in safety, consistency, and environmental control. Manual methods require operators to work in close proximity to high-pressure nozzles or abrasive blast guns, often at height or in confined spaces. MagTrack replaces that direct exposure with remote operation, which reduces the risk of pressure injection injuries, falls, and respiratory hazards from airborne particles.

In terms of surface preparation quality, a robotic crawler maintains a consistent nozzle-to-surface distance and travel speed throughout the cleaning pass. Manual operators naturally vary their technique, which can result in uneven cleaning patterns and inconsistent surface profiles. For offshore coating applications where the coating manufacturer specifies a defined surface cleanliness and roughness, robotic consistency translates directly into better coating adhesion and longer service life.

Environmental performance is another area where MagTrack outperforms open manual methods. Closed waterblasting and vacuum blasting configurations contain all waste within the system, preventing contaminated water and abrasive from entering the sea. This is increasingly important as offshore operators face tighter environmental regulations and greater scrutiny of discharge practices.

The trade-off is setup time and equipment logistics. Deploying a robotic crawler with its associated control unit, vacuum system, and high-pressure supply takes longer than setting up a manual lance. For very small, isolated areas of repair, manual methods may still be more time-efficient. However, for large-scale hull sections, tank interiors, or deck plating, MagTrack’s productivity advantage over manual methods becomes clear once the system is running.

How MagTrack supports your offshore maintenance operations

We developed MagTrack specifically to address the challenges that maintenance engineers and field technicians face in demanding industrial and offshore environments. Here is what the system brings to your offshore maintenance programme:

• Modular tooling: Switch between the Blast Can, Curved Blast Can, Swing Arm, and ReCycleBlaster to match the exact requirement of each surface and application.
• High-pressure capability: Water jetting tools operate from 500 to 3,000 bar “approximately 7,250 to 43,500 PSI”, covering everything from light washing to aggressive coating removal.
• ATEX Zone 2 certification: The MagTrack Mini is available in a certified version for use in potentially explosive atmospheres on oil and gas installations.
• Closed-circuit cleaning: Vacuum-assisted blast can configurations contain water and debris, meeting environmental compliance requirements and leaving a clean, dry surface ready for coating.
• Remote operation: Keep your team at a safe distance from the high-pressure zone, reducing injury risk and aligning with the safe working guidance published by SIR, EWJI, WJA, WJTA, and DIRV.
• Compact transport: The MagTrack Mini is lightweight and easy to move, making it practical for offshore logistics where deck space and lift capacity are limited.

If you are planning an offshore maintenance campaign and want to understand how MagTrack can fit into your scope of work, explore the full MagTrack product range or contact our team to discuss your specific requirements. We are ready to help you find the right configuration for your structure, your standards, and your schedule.