How is the MagTrack operated remotely?

The MagTrack is operated remotely using a handheld wireless controller that communicates with a main control unit, giving operators full command of the crawler’s movement, speed, and tool functions from a safe distance. This remote setup removes the operator from the immediate work zone, which is especially valuable during high-pressure water jetting operations where proximity to the blast area carries serious risk. The sections below answer the most common questions about how MagTrack remote operation works in practice.

What control system does the MagTrack use for remote operation?

The MagTrack uses a dedicated handheld remote controller paired with a main control unit. The remote controller sends signals to the control unit, which translates operator inputs into precise movements and tool commands on the crawler. This system gives operators real-time control over drive direction, speed, and attached tooling without needing to be physically near the machine.

Each MagTrack unit ships with the remote controller and main control unit as standard accessories, so operators do not need to source third-party control hardware. The interface is designed to be intuitive, which matters greatly in demanding field conditions where maintenance engineers and technicians need to focus on the job rather than wrestling with complicated controls. The MagTrack Mini, for example, includes these components as part of its standard package, making it straightforward to deploy even on compact or hard-to-reach surfaces.

For operations in potentially explosive atmospheres, the MagTrack is available as a certified ATEX Zone 2 unit. This certification means the control electronics and crawler hardware meet the strict requirements for use in hazardous areas such as offshore oil rigs or petrochemical facilities, where ignition risks must be tightly managed.

How far away can an operator safely control the MagTrack?

The MagTrack’s wireless remote control system is designed to give operators a meaningful standoff distance from the active work area, allowing them to position themselves well clear of high-pressure water jets and surface debris while still maintaining precise control of the crawler. The exact effective range depends on site conditions, but the system is built to support practical working distances on large industrial surfaces such as ship hulls, storage tanks, and steel structures.

This standoff capability is one of the most significant safety advantages of robotic water jetting compared to manual operation. Industry bodies including the SIR (Netherlands), EWJI (Europe), WJA (UK), WJTA (USA), and DIRV (Germany) all emphasize minimizing operator exposure to high-pressure jets as a core principle of safe water jetting practice. Remote operation directly supports these guidelines by keeping personnel at a safe distance during blasting.

On large surfaces like ship hulls or storage tank floors, operators can monitor the crawler’s progress visually while standing at a safe remove. For environments with limited sightlines, the optional LED light attachment improves visibility of the crawler’s position, helping operators maintain situational awareness without needing to move closer to the blast zone.

What surfaces and environments is the MagTrack designed for?

The MagTrack is designed for use on flat and slightly curved steel surfaces, making it suitable for a wide range of industrial environments including oil storage tanks, ship hulls, cargo holds, offshore platforms, and general industrial steel structures. The system’s magnetic drive keeps it firmly attached to vertical, horizontal, and overhead steel surfaces during operation.

The modular design of the MagTrack platform means the same carrier can be configured for different surface profiles. The standard blast can handles flat surfaces and mild curves, while the curved blast can is engineered for highly curved surfaces with a radius of up to 3 meters “approximately 9.8 feet”, making it well-suited for cleaning small storage tanks up to 6 meters “approximately 19.7 feet” in diameter and the curved contours of ship hulls.

The MagTrack Mini takes this further by being specifically optimized for narrow and confined spaces. Its compact footprint makes it easy to transport and deploy on offshore oil rigs, inside tanks, and in other tight environments where a larger crawler would not fit. It handles both straight and curved surfaces and is available as an ATEX Zone 2-certified unit for hazardous locations.

In terms of operating pressure, MagTrack tools work with high-pressure water across a range from 500 to 3,000 bar “approximately 7,250 to 43,500 PSI”, covering everything from light industrial cleaning through to aggressive surface preparation and paint removal.

How does the MagTrack maintain traction and positioning during operation?

The MagTrack maintains traction on steel surfaces through a system of height-adjustable magnets integrated into the crawler chassis. These magnets create a consistent pull toward the steel surface, keeping the crawler stable even on vertical walls and overhead sections. The magnetic force can be adjusted in height to fine-tune the balance between grip and the drag required to drive the crawler forward.

The MagTrack Mini illustrates this well. It features a height-adjustable main magnet along with omni-wheel rear support fitted with additional height-adjustable magnets. Two omni-wheels at the front support the blast can and allow smooth directional changes. The 2025 model introduced an improved drivetrain and a redesigned blast can with a better vacuum seal, which reduces the drag of the seal on the surface. This makes the crawler easier to drive while still maintaining a tight, dry seal during closed waterblasting.

The rotating manifold with 8 jet inserts inside the blast can ensures even coverage across the 180 mm “approximately 7.1 inches” cleaning path, so the crawler does not need to make multiple overlapping passes to achieve a thorough clean. This consistent coverage, combined with stable magnetic traction, means operators can drive at a steady pace and trust that the surface behind the crawler has been treated uniformly.

What safety features are built into the MagTrack’s remote operation?

The MagTrack’s remote operation model is itself the primary safety feature, as it removes the operator from the blast zone entirely during high-pressure water jetting. Beyond this fundamental separation, the system incorporates several additional safety-oriented design elements that align with the standards promoted by organisations such as the SIR (Netherlands), EWJI (Europe), WJA (UK), WJTA (USA), and DIRV (Germany).

Closed waterblasting with vacuum containment

The blast can operates as a closed waterblasting system connected to a vacuum unit. Water and debris are collected continuously during operation, preventing uncontrolled spray and surface runoff. This closed-circuit approach protects surrounding personnel and the environment, and is particularly important in sensitive locations such as oil storage facilities or marine environments where uncontained wastewater would create both safety and regulatory problems.

ATEX Zone 2 certification

For operations in potentially explosive atmospheres, the MagTrack is available as a certified ATEX Zone 2 unit. This certification confirms that the electrical components of the crawler and its control system meet the requirements for safe use in environments where flammable gases or vapours may be present, such as petrochemical plants and offshore platforms.

The redesigned blast can on the 2025 MagTrack Mini also includes a vacuum vent valve and wear plate, which contribute to reliable sealing performance and reduce the risk of unexpected pressure changes inside the blast can during operation. These design refinements reflect a systematic approach to reducing failure points that could compromise operator safety.

How does remote operation of the MagTrack compare to manual water jetting?

Remote robotic operation with the MagTrack delivers significant advantages over manual water jetting in terms of safety, consistency, and efficiency. Manual water jetting requires an operator to hold and direct the lance or gun in close proximity to the high-pressure stream, which creates direct exposure to risks including injection injuries, recoil, and debris impact. The MagTrack eliminates this proximity risk by keeping the operator at a safe distance from the active blast area.

Beyond safety, robotic operation tends to produce more consistent surface treatment results. A crawler maintains a fixed standoff distance between the jet inserts and the surface, and moves at a controlled, steady pace. Manual operators, by contrast, naturally vary their speed, angle, and distance, which can result in uneven cleaning or surface preparation quality. For applications where a specific surface profile is required before coating or painting, this consistency is a meaningful operational advantage.

Efficiency is another area where robotic operation stands out. The MagTrack can work continuously without the fatigue breaks that manual operators require, and its closed waterblasting system means there is no need to stop and manage wastewater separately. On large surfaces such as ship hulls or storage tank floors, this translates directly into faster project completion times.

Manual water jetting does retain advantages in highly irregular or confined geometries that a crawler cannot access, and it remains the appropriate choice for smaller, targeted cleaning tasks. The practical approach in most large-scale industrial cleaning operations is to use robotic systems like the MagTrack for the bulk of the surface area and reserve manual methods for edges, connections, and areas the crawler cannot reach.

How the MagTrack supports safer, more efficient operations

At DERC Salotech, we developed the MagTrack specifically to address the challenges that maintenance engineers, plant operators, and field technicians face every day in demanding industrial environments. Here is what the MagTrack brings to your operations:

• Remote control from a safe distance keeps operators well clear of high-pressure water jets operating between 500 and 3,000 bar “7,250 to 43,500 PSI”
• Closed waterblasting with vacuum collection eliminates uncontrolled water and debris, meeting the containment expectations set by organisations including the SIR, EWJI, WJA, WJTA, and DIRV
• Modular tooling adapts the same carrier to surface preparation, tank cleaning, cargo hold cleaning, abrasive blasting, inspection, and waterjet cutting
• ATEX Zone 2 certification makes it deployable in hazardous petrochemical and offshore environments
• Compact options like the MagTrack Mini extend robotic cleaning into narrow spaces and offshore rigs where larger equipment cannot go
• Consistent, repeatable coverage reduces rework and supports coating-ready surface quality on the first pass

If you want to see how the MagTrack fits your specific application, explore the full MagTrack product range or get in touch with our team to discuss your requirements directly.