How does the MagTrack fit through a 24-inch manhole?

The MagTrack fits through a 24-inch “61 cm” manhole because its modular carrier is designed to be disassembled into compact sections that pass through standard confined space entry points. Once inside, the robot is reassembled directly within the vessel. This compact-by-design philosophy is central to how MagTrack brings robotic cleaning into spaces that have historically required manual entry.

Below, we answer the most common questions about MagTrack’s confined space capabilities, from how it enters a vessel to what that means for operator safety and overall cleaning performance.

How is the MagTrack designed to fit through tight openings?

MagTrack is built around a modular universal carrier that can be broken down into sections small enough to pass through a standard 24-inch “61 cm” industrial manhole. The system is not forced through as a single rigid unit. Instead, each component is sized and shaped so that technicians can hand it through the opening piece by piece and reassemble it on the other side.

This modular approach is a deliberate engineering choice, not an afterthought. In industrial environments such as oil storage tanks, cargo holds, and pressure vessels, manhole dimensions are often fixed by design and regulation. Equipment that cannot enter through those openings simply cannot be used inside them. By designing the carrier and its interchangeable tool attachments to be separable, MagTrack eliminates that barrier entirely.

The MagTrack Mini takes this a step further. It is the smallest available MagTrack variant, a lightweight two-wheel-drive crawler with a fixed blast can that is specifically engineered for narrow spaces. Its compact footprint makes it easy to transport to site and straightforward to lower through confined entry points, including those found on offshore oil rigs where access is especially restricted.

Key design features that enable entry through tight openings include:

• A modular build that separates into manageable, hand-passable components
• Compact overall dimensions, particularly in the MagTrack Mini variant
• Lightweight construction that reduces the physical effort needed during entry and exit
• Tool attachments that connect and disconnect without specialist tooling inside the vessel

What happens to the MagTrack once it’s inside the vessel?

Once the components have been passed through the manhole, the MagTrack is reassembled inside the vessel and immediately adheres to the steel surface using its height-adjustable magnetic system. From that point, it operates as a fully remote-controlled robotic crawler, driven by an operator stationed safely outside the confined space.

The crawler moves across flat and slightly curved steel surfaces using its electrically driven wheel system. The MagTrack Mini features a two-wheel-drive configuration with omni-wheels at the front and rear for smooth navigation, while the standard carrier supports four-wheel drive for heavier-duty applications. The height-adjustable magnet allows the robot to maintain consistent grip even when surface conditions vary, such as on plates with minor deformation or weld seams.

Depending on the task, the carrier is fitted with the appropriate modular tool before or after entry. For closed waterblasting, the blast can is attached in front of the carrier and connected via hose to a vacuum unit positioned outside the vessel. The vacuum unit draws water and debris away continuously, so there is no pooling of contaminated water inside the confined space. For surface preparation work, the curved blast can handles surfaces with a radius of up to 3 meters “approximately 10 feet”, making it suitable for smaller tanks and the curved contours of ship hulls.

Throughout the cleaning run, the operator uses a remote controller to steer the robot, adjust tool height, and monitor the cleaning path. The rotating manifold on the blast can delivers high-pressure water jets across a 180 mm “approximately 7 inches” cleaning path per pass, operating at pressures ranging from 500 to 3,000 bar “7,250 to 43,500 PSI”.

What types of vessels and confined spaces can the MagTrack enter?

MagTrack is designed to enter and operate in any steel-walled confined space with a manhole or access hatch large enough to pass its modular components through. In practice, this includes oil storage tanks, cargo holds, pressure vessels, ballast tanks, and industrial process vessels across petrochemical, energy, marine, and manufacturing sectors.

The range of compatible environments is broad because the system’s performance depends on two conditions: a steel surface for the magnets to grip, and an access opening large enough for component-by-component entry. Beyond those requirements, MagTrack adapts to the specific geometry of the space through its selection of modular tools.

Environments where MagTrack is regularly deployed include:

• Oil and fuel storage tanks where old coatings, sludge, and scale must be removed before recoating
• Cargo holds on vessels where residue from previous loads must be cleaned to cargo-ready standard
• Ship hulls and ballast tanks where curved steel surfaces require the curved blast can attachment
• Offshore oil rig structures where the MagTrack Mini’s compact form is particularly valuable given space constraints on platforms
• Industrial process vessels in petrochemical and energy plants where internal cleaning is part of routine maintenance cycles

For environments classified as potentially explosive atmospheres, MagTrack is available as a certified ATEX Zone 2 unit, which broadens the range of petrochemical and offshore locations where it can legally and safely operate.

How does manhole entry affect operator safety during robotic jetting?

Manhole entry is one of the most significant safety risks in confined space cleaning. When MagTrack enters a vessel through the manhole instead of an operator, it removes the human body from the most hazardous phase of the operation entirely. The operator remains outside, controlling the robot remotely, which eliminates exposure to the risks associated with confined space entry.

Confined space entry carries serious risks: oxygen deficiency, toxic atmospheres, restricted rescue access, and exposure to high-pressure water jets. Safety organisations including SIR (Netherlands), EWJI (Europe), WJA (UK), WJTA (USA), and DIRV (Germany) all publish guidelines that emphasise minimising the time personnel spend inside confined spaces during high-pressure cleaning operations. Robotic systems like MagTrack directly support compliance with those guidelines by reducing or eliminating the need for manned entry during the cleaning phase.

The closed waterblasting configuration adds a further safety dimension. The blast can’s vacuum seal collects water and debris at the source, meaning there is no spray mist or ricocheting debris accumulating inside the vessel. This keeps the internal environment cleaner and reduces the contamination load that would otherwise require additional ventilation or personal protective equipment management.

From a practical standpoint, the operator’s role shifts from physical cleaning work inside a hazardous space to monitoring and steering from a safe position outside. This also reduces fatigue-related errors, which are a recognised contributor to incidents in prolonged confined space operations.

How does the MagTrack compare to manual confined space cleaning?

Manual confined space cleaning requires one or more operators to enter the vessel, wear full personal protective equipment, and perform high-pressure jetting or blasting by hand. MagTrack replaces the majority of that manned work with a remotely operated crawler, reducing human exposure time, improving consistency, and typically completing the cleaning cycle faster.

The differences are most visible across four areas:

• Safety exposure: Manual cleaning places operators inside a confined space for extended periods. MagTrack keeps operators outside throughout the cleaning run, reducing confined space exposure time to entry and exit checks only.
• Cleaning consistency: A robot maintains a fixed speed, pressure, and tool distance from the surface on every pass. Manual operators are subject to fatigue, posture limitations, and variable technique, particularly in awkward spaces. The MagTrack’s rotating manifold delivers a consistent 180 mm “approximately 7 inches” cleaning path at pressures up to 3,000 bar “43,500 PSI” on every pass.
• Waste management: The closed blast can system collects water and debris continuously via vacuum, leaving a dry surface ready for inspection or coating. Manual open jetting typically requires additional time for water management and surface drying before follow-on work can begin.
• Personnel requirements: Manual cleaning in confined spaces typically requires a standby person, a safety attendant, and the cleaning operator as a minimum. Robotic cleaning reduces the number of people directly exposed to the hazardous environment while the cleaning work is underway.

Manual cleaning still has a role in spaces where a robot cannot navigate, or for finishing work in corners and edges that a crawler cannot reach. In practice, the most efficient approach often combines robotic coverage for the large flat and curved surfaces with targeted manual finishing for areas the robot cannot access.

How MagTrack helps with confined space cleaning

MagTrack brings together compact design, modular tooling, and remote operation to make confined space cleaning safer and more efficient. Here is what that means in practice:

• Passes through standard 24-inch “61 cm” manholes as disassembled components, then reassembles inside the vessel
• Operates on flat and curved steel surfaces with magnetic adhesion and adjustable grip
• Delivers closed waterblasting at pressures from 500 to 3,000 bar “7,250 to 43,500 PSI” with continuous vacuum debris collection
• Keeps operators outside the confined space during the cleaning run, directly supporting the safety standards set by SIR, EWJI, WJA, WJTA, and DIRV
• Available in ATEX Zone 2 certified configuration for explosive atmosphere environments
• Modular tool system covers surface preparation, cargo hold cleaning, tank cleaning, inspection, and more from a single carrier platform

If you are evaluating robotic confined space cleaning for your next project, explore the full MagTrack product range to find the configuration that fits your vessel dimensions and cleaning requirements. For specific questions about manhole dimensions, tool selection, or ATEX certification, contact our team directly and we will help you find the right solution.