How does the MagTrack handle curved tank walls?

The MagTrack handles curved tank walls by using height-adjustable magnets and a modular tool system specifically engineered for curved steel surfaces. Its Curved Blast Can variant is designed to conform to radii of up to 3 meters (“approximately 9.8 feet”), making it well-suited for storage tanks up to 6 meters (“approximately 19.7 feet”) in diameter and the curved contours of ship hulls. Below, we unpack the geometry it can navigate, how its magnetic grip works on curves, and where it delivers the most value in real industrial settings.

What surface geometries can the MagTrack actually navigate?

The MagTrack is designed to operate on flat and slightly curved steel surfaces, with specialized tooling that extends its capability to highly curved geometries with a radius of up to 3 meters (“approximately 9.8 feet”). This means it covers a broad spectrum of industrial steel structures, from the near-flat walls of large storage tanks to the tighter curves found on smaller vessels and ship hulls.

In practical terms, the system handles several distinct surface types:

• Flat and near-flat steel panels – the standard operating environment for the four-wheel universal carrier, found on large tank walls, ship decks, and structural steelwork
• Slightly curved surfaces – common on larger oil storage tanks, where the curvature is gradual enough for the standard blast can to maintain consistent contact
• Highly curved surfaces up to 3 meters (“approximately 9.8 feet”) radius – addressed by the Curved Blast Can, which is engineered specifically for smaller storage tanks and ship hull profiles
• Narrow and confined spaces – the MagTrack Mini, the most compact crawler in the range, handles both straight and curved surfaces while fitting into areas that larger robots cannot reach

The key to this geometric flexibility lies in the modular architecture. Rather than designing a single robot for a single surface type, we built the MagTrack around a universal carrier that accepts interchangeable tool heads. When the geometry changes, the operator swaps the tool rather than replacing the entire system. This makes the MagTrack genuinely adaptable across a wide range of real-world industrial structures rather than being optimized for one idealized surface.

How does the magnetic adhesion system maintain grip on curved steel?

The MagTrack maintains grip on curved steel through a height-adjustable magnet system combined with omni-wheel support, which allows the crawler to distribute magnetic force across the contact surface even as the angle of the steel changes. Adjustable magnet height lets operators fine-tune the pull force relative to the curvature, keeping the crawler stable without losing traction.

On a flat surface, magnetic adhesion is straightforward: the magnet sits at a consistent distance from the steel and delivers uniform pull. On a curved surface, the geometry introduces a changing angle between the magnet and the steel, which can reduce effective pull force if the system is not designed to compensate. The MagTrack addresses this in two ways.

First, the height-adjustable magnet on the MagTrack Mini allows the operator to set the magnet closer to or farther from the surface depending on the curvature encountered. A tighter curve requires a closer magnet position to maintain adequate adhesion. Second, the omni-wheel rear support includes extra height-adjustable magnets, which add supplementary grip points at the rear of the crawler. This distributed magnetic contact prevents the robot from tipping or losing adhesion at the trailing edge when navigating convex or concave profiles.

The result is a crawler that can transition between surface geometries during a single job without requiring manual intervention to reconfigure the adhesion system from scratch. For maintenance engineers working on structures with varied geometry, this continuity of grip is a meaningful operational advantage.

What happens to water jetting performance on non-flat surfaces?

Water jetting performance on non-flat surfaces depends heavily on the tool head in use. With the right modular attachment, the MagTrack delivers consistent high-pressure cleaning across curved geometries without a meaningful drop in cleaning quality. The Curved Blast Can, for instance, maintains its vacuum seal and cleaning path effectiveness on surfaces with a radius of up to 3 meters (“approximately 9.8 feet”), operating at pressures from 500 bar (“approximately 7,250 PSI”) up to 3,000 bar (“approximately 43,500 PSI”).

The challenge with water jetting on curved surfaces is maintaining the correct standoff distance between the jet inserts and the steel. If the blast can lifts away from the surface due to curvature, the jets lose energy before impact, reducing cleaning effectiveness. If it presses too hard, the vacuum seal can deform or drag, creating resistance that strains the drivetrain and risks inconsistent results.

The Curved Blast Can is engineered with a bellows-style seal design that conforms to the surface profile rather than holding a rigid flat contact. This flexible perimeter maintains the vacuum dome’s integrity even as the surface curves beneath it, which keeps both water and debris contained within the closed-circuit system. The rotating manifold with 8 jet inserts ensures even coverage across the 180 mm (“approximately 7 inches”) cleaning path regardless of the surface angle.

For open water blasting on curved structures like wind girders or complex fabrications, the Swing Arm attachment offers a different approach. Its adjustable actuator allows the operator to set the distance from the cleaning head to the surface while the robot is in motion, compensating for geometry changes in real time without stopping the job.

Which tank types and industries use the MagTrack on curved walls?

The MagTrack is used on curved steel walls across petrochemical, energy, marine, and general industrial maintenance sectors. The most common applications involve oil storage tank cleaning, cargo hold cleaning on vessels, and surface preparation on ship hulls, all of which involve curved steel profiles that benefit directly from the Curved Blast Can’s capability.

Oil and petrochemical storage tanks

Smaller oil storage tanks, typically those up to 6 meters (“approximately 19.7 feet”) in diameter, present curved wall profiles that the standard flat blast can cannot address effectively. The Curved Blast Can was developed specifically for this context, allowing closed waterblasting operations that collect all water and debris without leakage. This is particularly important in petrochemical environments where contamination control is a regulatory and safety requirement. Safety in these environments is governed by organizations including SIR in the Netherlands, EWJI in Europe, WJA in the UK, WJTA in the USA, and DIRV in Germany, all of which set standards for how high-pressure jetting operations must be conducted.

Marine and offshore applications

Ship hulls present some of the most demanding curved surface challenges in industrial cleaning. The compound curves of a hull require a tool that can maintain vacuum seal integrity across changing radii. Cargo hold cleaning, paint removal from hull surfaces, and surface preparation prior to recoating are all tasks where the MagTrack’s curved surface capability translates directly into faster turnaround and reduced manual labour. The MagTrack Mini’s compact design also makes it well-suited for offshore oil rigs, where space constraints are a constant operational factor.

How does the MagTrack compare to manual jetting on curved surfaces?

Compared to manual high-pressure water jetting on curved surfaces, the MagTrack offers consistent standoff distance, continuous operation without operator fatigue, and closed-circuit debris collection that manual jetting cannot replicate. Manual operators working on curved tank walls or ship hulls face variable technique, physical strain, and exposure to high-pressure rebound, all of which the robotic system eliminates.

Manual jetting on curved surfaces is physically demanding because the operator must constantly adjust their body position and tool angle to follow the geometry. This leads to inconsistent coverage, particularly at the transitions between flat and curved sections, and increases the risk of missed areas that require rework. Operator fatigue compounds this over a full shift, reducing both quality and safety margins.

The MagTrack maintains a fixed relationship between the jet inserts and the steel surface throughout the cleaning pass. The robot moves at a controlled, consistent speed, which means dwell time per unit area remains constant. In a closed waterblasting configuration, all water and debris are captured by the vacuum unit, leaving a clean and dry surface ready for coating or inspection without additional cleanup steps.

From a safety perspective, removing the operator from direct proximity to the high-pressure jets is a fundamental improvement. Organizations such as SIR, EWJI, WJA, WJTA, and DIRV all emphasize reducing human exposure to high-pressure water jetting hazards as a core principle of safe operations. Robotic deployment directly supports compliance with these guidelines.

The productivity difference is also significant on longer jobs. A robot does not require rest breaks, does not vary its technique, and can be monitored remotely via the control unit, allowing one technician to oversee the operation rather than having multiple operators working simultaneously in a hazardous zone.

How the MagTrack helps with curved surface cleaning

We developed the MagTrack specifically to solve the challenges that curved steel surfaces present in industrial cleaning and surface preparation. Whether you are working on a small oil storage tank, a ship hull, or an offshore structure, the system is built to adapt rather than compromise.

Here is what the MagTrack brings to curved surface operations:

• Curved Blast Can with flexible bellows seal for closed waterblasting on surfaces up to 3 meters (“approximately 9.8 feet”) radius, operating at up to 3,000 bar (“approximately 43,500 PSI”)
• Height-adjustable magnets and omni-wheel support to maintain consistent grip across changing surface geometries
• MagTrack Mini for compact, narrow-space applications on both straight and curved surfaces, including offshore environments
• Modular tool system that lets you switch between closed waterblasting, open jetting, abrasive blasting, and inspection without replacing the crawler
• Remote-controlled operation that keeps operators away from high-pressure hazards while maintaining full control of the cleaning process
• Clean, dry surface results from the vacuum-integrated blast can, reducing post-cleaning preparation time before coating or inspection

If you are evaluating robotic cleaning solutions for curved tank walls or other complex steel structures, explore the full MagTrack product range or contact our team to discuss the right configuration for your specific application.