How does the MagTrack robot stay attached to vertical steel surfaces?

The MagTrack robot stays attached to vertical steel surfaces through a system of powerful permanent magnets integrated into the crawler’s chassis. These magnets generate a continuous attractive force against ferromagnetic steel, requiring no power to maintain adhesion. The result is a crawler that holds firm even under the reactive forces produced by high-pressure water jetting at up to 3,000 bar “43,511 PSI”.

This magnetic adhesion principle is what makes MagTrack fundamentally different from suction-based wall-climbing systems. Because the magnets are permanent rather than electromagnetically powered, the robot does not lose grip if there is a power interruption. The sections below explore exactly how strong that grip is, which surfaces it works on, and what safeguards are in place for demanding real-world conditions.

How strong is the magnetic force keeping MagTrack on steel?

The magnetic force in the MagTrack system is engineered to exceed the combined downward pull of the robot’s own weight and the reactive thrust generated by high-pressure water jets operating up to 3,000 bar “43,511 PSI”. The magnets are dimensioned specifically for industrial water jetting loads, not just for static adhesion, which means the holding force accounts for dynamic operational stress.

The MagTrack Mini, the most compact unit in the family, features a height-adjustable main magnet combined with omni-wheel rear supports that carry additional height-adjustable magnets. This multi-point magnetic architecture distributes the holding load across the chassis rather than concentrating it at a single point. The practical effect is a more stable platform that resists both vertical sliding and rotational tipping forces that occur when a jetting head pushes against a surface.

It is worth noting that magnetic holding force is sensitive to the condition of the steel surface. Thick layers of paint, heavy scale, or deep corrosion pitting can create an air gap between the magnet and the base metal, reducing effective pull. This is one reason why MagTrack is often deployed in progressive cleaning passes, where each pass improves the surface condition and, in turn, the consistency of magnetic contact on subsequent runs.

What types of steel surfaces can MagTrack operate on?

MagTrack crawlers are designed for flat and slightly curved ferromagnetic steel surfaces. The standard carrier handles flat plates and gentle curves comfortably, while the Curved Blast Can attachment extends capability to surfaces with a radius of up to 3 meters “approximately 9.8 feet”, making it suitable for small storage tanks up to 6 meters “approximately 19.7 feet” in diameter and for the curved hull sections of ships.

The key requirement is that the substrate must be ferromagnetic steel. Stainless steel grades that are austenitic, aluminium, fibreglass, and concrete are not compatible with magnetic adhesion. In industrial maintenance, this means MagTrack is ideally matched to carbon steel structures: oil storage tanks, ship hulls, cargo holds, offshore platform decks, and structural steelwork in petrochemical plants.

Surface geometry matters beyond simple curvature. Edges, weld seams, stiffeners, and wind girders can interrupt the crawler’s path. The (Tilt) Swing Arm attachment addresses this by allowing the cleaning head to be repositioned in height and angle while the robot is in motion, so the operator can adapt to structural features without stopping the run. For narrow or confined areas, the MagTrack Mini’s compact footprint makes it the preferred choice, and it is rated for use on offshore oil rigs where deck and hull access is often restricted.

How does MagTrack maintain traction while jetting at high pressure?

MagTrack maintains traction during high-pressure water jetting through the combination of permanent magnetic adhesion and an electrically driven wheel system that is sized to overcome both the reactive thrust of the jetting tools and the drag created by the blast can seal on the surface. The drive system and magnet strength are matched as an integrated package, not treated as independent components.

At pressures up to 3,000 bar “43,511 PSI”, the water jets produce a significant reactive force pushing the cleaning head away from the surface. The blast can’s vacuum dome counteracts part of this by maintaining negative pressure inside the cleaning zone, which simultaneously collects water and debris and pulls the dome closer to the surface. This dual function means the vacuum system actively assists traction rather than being a passive containment measure.

The 2025 model of the MagTrack Mini introduced an improved drivetrain alongside a redesigned blast can featuring new bellows, a wear plate, and a vacuum vent valve. The improved vacuum seal reduces drag on the surface, which makes the robot easier to drive while preserving the suction-assisted grip. For operators, this translates to smoother traversal across large surface areas without the fatigue-inducing resistance that older seal designs could produce.

Operator control is handled through a remote controller, keeping personnel at a safe distance from the high-pressure jetting zone. Safety organisations including SIR in the Netherlands, EWJI across Europe, WJA in the UK, WJTA in the USA, and DIRV in Germany all emphasise standoff distance as a primary risk control measure in water jetting operations. Remote-controlled robotic systems like MagTrack directly support this requirement by removing the operator from the immediate hazard area.

What happens if MagTrack loses contact mid-operation?

If MagTrack loses magnetic contact mid-operation, the robot will slide or fall from the surface. Because the magnets are permanent, there is no electrical failsafe that can restore adhesion once physical contact is broken. This makes preventing loss of contact the priority, rather than relying on any recovery mechanism after the fact.

In practice, loss of contact is most likely to occur at surface transitions: edges, large weld beads, access hatches, or areas of severe corrosion where the steel has lost structural integrity. Operators are trained to identify these zones during pre-operation inspection and to plan the robot’s path to avoid abrupt transitions. Where edges cannot be avoided, the approach speed is reduced and the operator monitors the robot’s behaviour closely via the remote control.

The multi-point magnetic design of the MagTrack system provides some tolerance for minor surface irregularities. If one wheel momentarily loses contact over a weld seam or surface protrusion, the remaining magnets maintain the overall adhesion of the chassis. Complete loss of contact across all magnetic contact points simultaneously is far less likely than a single-point failure, which is why the distributed magnet architecture is a deliberate safety design choice.

Proper operator training is essential for managing these risks. DERC Salotech’s subsidiary DERC Adviesgroep offers certified training courses covering safe operation of robotic water jetting equipment, aligned with the standards promoted by safety bodies such as SIR, EWJI, WJA, WJTA, and DIRV. Understanding the robot’s limits is as important as understanding its capabilities.

How does MagTrack compare to vacuum-based wall-climbing robots?

MagTrack and vacuum-based wall-climbing robots represent two fundamentally different adhesion philosophies. MagTrack uses permanent magnets, which require no power to maintain grip and work reliably on ferromagnetic steel regardless of surface porosity. Vacuum-based systems use negative air pressure to adhere, which makes them applicable to a wider range of materials but introduces a dependency on continuous suction generation and surface airtightness.

Adhesion reliability under industrial conditions

Permanent magnetic adhesion is inherently more robust in environments where surface contamination, water, debris, and irregular geometry are constant factors. A vacuum cup or vacuum pad loses suction quickly if the seal is broken by a weld seam, surface pit, or debris particle. Magnetic force, by contrast, acts through thin layers of paint, water film, and minor surface irregularities without requiring a sealed boundary. In the context of high-pressure water jetting, where the working surface is continuously wetted, this is a significant practical advantage.

Power dependency and operational continuity

Vacuum systems require continuous power for their suction pumps. A power interruption means immediate loss of adhesion, which is a serious safety risk on a vertical surface. Permanent magnets in MagTrack hold the robot in place even if the electrical drive system is cut. The robot stops moving but remains attached, giving operators time to assess the situation and retrieve the unit safely. This characteristic makes magnetic crawlers the preferred choice in environments where power supply reliability cannot be guaranteed, such as offshore platforms or remote industrial sites.

The trade-off is surface compatibility. Vacuum robots can operate on non-ferrous materials, making them relevant for aluminium ship structures, concrete walls, or composite panels. MagTrack’s application range is limited to ferromagnetic steel, but within that domain, it delivers a level of adhesion reliability and operational simplicity that vacuum systems find difficult to match under the same conditions.

How MagTrack supports safe and efficient surface operations

MagTrack brings together magnetic adhesion, remote operation, and a modular tool system to address the real challenges that maintenance engineers, operators, and field technicians face every day on steel structures. Here is what the system delivers in practice:

• Operator safety: Remote-controlled operation keeps personnel away from high-pressure jetting zones, directly supporting the standoff distance requirements promoted by SIR, EWJI, WJA, WJTA, and DIRV.
• Surface versatility: Modular attachments including the Blast Can, Curved Blast Can, Swing Arm, and ReCycleBlaster cover closed waterblasting, open blasting, and vacuum abrasive blasting from a single carrier platform.
• Closed-circuit cleaning: The vacuum dome collects water and debris without leakage, leaving a clean, dry surface ready for coating or inspection immediately after the pass.
• Compact deployment: The MagTrack Mini fits into narrow spaces, including offshore rigs, and is available as a certified ATEX Zone 2 unit for use in explosive atmospheres.
• High-pressure capability: All water jetting tools operate up to 3,000 bar “43,511 PSI”, covering the full range of industrial cleaning and surface preparation demands.
• Reduced environmental impact: The ReCycleBlaster attachment recycles abrasive media in a closed circuit, cutting material costs and preventing harmful particles from entering the atmosphere.

We engineer every MagTrack configuration around the specific demands of your operation, whether that is oil storage tank cleaning, ship hull preparation, cargo hold washing, or structural inspection. If you want to see the full product range and technical specifications, visit the MagTrack product page. To discuss your specific application with our team, contact us directly and we will help you identify the right configuration for your site conditions and pressure requirements.