Industrial magnetic mats

Metal shavings, filings, small metal fragments and other fine ferromagnetic particles can become lodged in the soles of work shoes. Employees may then unknowingly carry them into offices, warehouses, inspection rooms or cleaner production areas.

A magnetic mat creates a transition zone that employees walk across when leaving a workshop or production area. Powerful permanent magnets positioned beneath a rubber cover attract ferromagnetic particles from the soles of their shoes and help prevent them from spreading further.

What is a magnetic industrial mat?

A magnetic industrial mat is a cleaning device consisting of a magnetic base and a removable rubber walking surface. The magnetic section contains powerful neodymium magnets distributed underneath the surface of the mat.

The mat is placed in a busy area through which employees pass between a contaminated and a cleaner part of the facility. When they step on the mat, metal contaminants on the soles of their shoes are attracted towards the magnetic core and remain captured on the rubber surface.

How does a magnetic mat work?

Permanent magnets beneath the rubber layer create a magnetic field. When a ferromagnetic particle, such as a steel shaving or iron filing, enters this field, the magnet attracts it towards the surface of the mat.

The rubber layer provides a safe walking surface while separating the footwear from the magnetic core. Captured particles remain on the rubber cover until the mat is cleaned.

What affects capture efficiency?

• size and weight of the metal particle,
• magnetic properties of the material,
• distance between the particle and the magnets,
• thickness of the rubber layer,
• number and arrangement of the magnets,
• contamination and wear of the mat,
• the employee's walking speed and movement,
• the shape and depth of the tread on the work shoes.

Why is the distance from the magnet important?

Magnetic force decreases rapidly with distance. A particle lodged deep inside the coarse tread of a work boot may be farther away from the magnetic core than a particle lying on a flat part of the sole.

For this reason, it is not possible to guarantee that every individual contaminant will be captured under all conditions. The effectiveness of the mat should be verified directly in the specific workplace using the actual work footwear.

Which contaminants can a magnetic mat capture?

The mat primarily captures ferromagnetic materials that can be attracted by a standard permanent magnet.

Typical captured contaminants

• steel shavings,
• iron filings,
• ferromagnetic metal dust,
• small pieces of steel sheet,
• wire fragments,
• small screws,
• nuts and washers,
• offcuts of magnetic steel,
• particles produced by grinding and machining ferrous materials.

What will a magnetic mat not capture?

A magnetic mat will not capture ordinary non-magnetic contaminants or metals that are not ferromagnetic.

• dust and sand without ferrous content,
• plastic chips,
• wood sawdust,
• glass,
• aluminium,
• copper,
• brass,
• some grades of stainless steel,
• oil and other liquid contaminants.

Where are magnetic mats used?

Magnetic mats are mainly installed at transition points between areas where metal contaminants occur and areas where a higher level of cleanliness is required.

Metalworking and engineering

The mat can be placed at the exit of a machining workshop, grinding shop, metalworking area or other facility where metal components are manufactured.

Food-processing facilities

A magnetic mat can form part of a transition zone between maintenance, workshop or technical areas of a facility and the food-production area.

However, the presence of a mat alone does not automatically mean that hygiene or audit requirements are met. The entire approved workplace hygiene system and the company's internal procedures must be followed.

Automotive industry

It helps reduce the transfer of metal shavings from machining and assembly areas into warehouses, offices, inspection zones or other parts of the production line.

Production and service workshops

The mat can be used between a workshop and an administrative area, changing room, corridor or finished-goods warehouse.

Laboratories and inspection areas

It can help protect more sensitive measuring and inspection areas from ferromagnetic shavings carried in from nearby production areas.

Recycling and processing facilities

It is also suitable for areas where metal waste, crushed material or components that may leave small ferromagnetic fragments are handled.

Where should a magnetic mat be placed?

Correct positioning determines whether employees will actually walk across the mat and whether it will be able to perform its intended function.

Suitable placement

• directly in a doorway,
• in a narrow transition corridor,
• at the exit from a workshop,
• before entering a cleaner zone,
• on a flat and stable surface,
• in a location that cannot easily be bypassed.

Unsuitable placement

• next to a doorway where employees can walk around it,
• on an uneven or slippery floor,
• in an area with permanently standing water,
• on a step or edge,
• in the path of forklifts or other handling equipment unless approved by the manufacturer,
• near equipment sensitive to magnetic fields.

Does the employee need to step on the mat with both feet?

For better performance, the zone should be large enough for employees to naturally step onto it with both feet. With a small mat, some employees may cross it with only one step or partially miss it when walking quickly.

What size magnetic mat should you choose?

Common sizes include 500 × 500 mm and 1,000 × 500 mm. A larger area increases the contact time between the footwear and the magnetic field and makes it more likely that the employee will step onto the mat with both feet.

500 × 500 mm mat

The compact version is suitable for smaller passageways, individual workstations or areas where space is limited.

It is lighter and easier to carry and clean. However, it must be positioned so that employees cannot simply step over or walk around it.

1,000 × 500 mm mat

The longer mat creates a larger transition area. It is suitable for main walkways and locations with higher employee traffic.

The larger size may increase the likelihood of several steps being taken on the magnetic surface, but it also means greater weight and higher demands during cleaning and storage.

What is a magnetic mat made of?

The basic design consists of two main parts – a rubber walking cover and a magnetic base.

1. Upper rubber layer

The rubber cover creates the walking surface and protects the magnetic section from direct mechanical contact with footwear.

Its purpose is to:

• retain attracted metal particles on the surface,
• protect the magnets against impacts and scratches,
• provide a safer walking surface,
• allow easy removal during cleaning,
• reduce direct contact between contaminants and the magnetic base.

2. Lower magnetic layer

Powerful neodymium magnets are distributed underneath the rubber cover. Their magnetic field passes through the rubber layer and attracts ferromagnetic contaminants.

How does rubber thickness affect performance?

A thicker rubber layer can provide better protection against wear and extend the service life of the walking surface. At the same time, however, it increases the distance between the magnets and the metal particle.

A thinner layer allows the magnetic field to act on particles from a shorter distance, but it may be more susceptible to mechanical damage.

Standard, ECO and UP versions

The individual versions differ in construction, weight, magnet arrangement, rubber layer, ease of cleaning and price level.

Standard magnetic mat

The Standard version offers a high magnetic field density and a removable rubber cover. It is suitable for general industrial use and regular capture of metal contaminants from footwear.

ECO magnetic mat

The ECO version is a more economical option. It may contain fewer magnets or have a lower magnetic field density than the Standard version.

It is suitable for less demanding applications or areas with lower levels of ferromagnetic contamination. Suitability should be verified by practical testing.

UP magnetic mat

The UP version uses a rigid plastic structure and a rubber cover secured around the perimeter with magnetic tape. The construction makes it easier to remove the rubber layer during cleaning and to handle the mat.

The UP version is suitable for facilities where a more robust construction, easier maintenance and frequent cleaning are important.

Magnetic mat and magnetic capture zone

The terminology may vary depending on the design and intended use. A magnetic mat usually forms a complete walking surface, while a magnetic capture zone may be designed as a lighter transition section or modular surface.

When choosing a product, therefore, do not rely on its name alone. Consider its specific dimensions, weight, construction and measured values.

Magnetic flux density and pull-off force

Two basic values may be specified for magnetic mats – magnetic flux density in gauss and pull-off force in newtons.

Magnetic flux density in Gs

Magnetic flux density describes the intensity of the magnetic field at a specific measurement point. The value may differ directly on the magnetic core and above the rubber cover.

The rubber layer increases the distance from the magnets, so the measured value at its surface is usually lower.

Pull-off force in N

Pull-off force indicates the force required to separate a defined steel test piece from the measured surface under specified conditions.

Why is it not enough to compare just one value?

The effectiveness of the mat is also influenced by:

• distribution of magnets across the entire surface,
• number of magnetic points,
• rubber thickness,
• size of the tested particle,
• dimensions of the mat,
• the way employees walk across it,
• condition and cleanliness of the walking surface.

How should a magnetic mat be used correctly?

1. Place the mat on a flat, clean and stable floor.
2. Check that it does not move or lift at the edges.
3. Position it so that employees cannot walk around it.
4. Mark the transition zone and train employees.
5. When crossing the mat, step onto it with both feet.
6. Regularly check the amount of captured particles.
7. Clean the mat before a thick layer of metal builds up on its surface.
8. After cleaning, check that the rubber cover is correctly positioned.

Should employees wipe their shoes on the mat?

Several controlled steps may help improve capture efficiency. However, aggressive scraping or kicking the mat can damage the rubber layer or move sharp metal shavings across the surface.

How often should a magnetic mat be cleaned?

There is no universal cleaning interval. It depends on the amount of metal particles in the workplace, number of employees, type of footwear and frequency of foot traffic.

The mat should be cleaned particularly when:

• a larger amount of shavings is visible on the surface,
• metal particles begin to accumulate in one area,
• sharp fragments could damage the rubber,
• particles remain on footwear even after walking across the mat,
• the mat begins to become slippery or uneven,
• cleaning is required by the internal maintenance plan or audit.

When the mat is first introduced into operation, it is advisable to inspect it several times during a shift. A suitable cleaning interval can then be established according to the actual amount of captured contamination.

How do you clean a magnetic mat?

The main advantage of the design is the ability to separate the rubber layer from the magnetic core. As soon as the cover is moved away from the magnets, the holding force acting on the captured particles decreases significantly.

1. Prevent employees from walking through the area while it is being cleaned.
2. Wear work gloves resistant to sharp edges.
3. Carefully remove the rubber cover from the magnetic base.
4. Move the cover to the designated cleaning area.
5. Shake off or wipe away captured ferromagnetic particles.
6. Remove fine shavings with a brush or suitable scraper.
7. Check the rubber for embedded sharp fragments.
8. Clean the magnetic base.
9. Inspect the rubber, structure and magnets for damage.
10. Return the rubber cover to the correct position.
11. Check that the mat lies flat and does not present a trip hazard.

How can you extend the service life of a magnetic mat?

• Regularly remove captured metal contaminants.
• Do not leave sharp shavings embedded in the rubber for long periods.
• Do not drive pallet trucks or forklifts over the mat unless approved by the manufacturer.
• Protect it from oil, aggressive chemicals and high temperatures.
• Do not lift it by only one corner when moving it.
• Do not fold it over a sharp edge.
• Inspect the condition of the magnetic base and plastic construction.
• Allow all components to dry completely after wet cleaning.
• Store it flat in a dry place.

How do you choose a suitable magnetic mat?

Surface area

A larger surface increases the likelihood that employees will step on the mat several times. In narrow areas, however, a smaller version may be more practical.

Weight

A heavier mat may remain more stable on the floor but is more difficult to move and clean. The lighter plastic construction of the UP version makes handling easier.

Magnetic performance

Higher performance is useful where finer particles occur or where a thicker rubber layer must be overcome. However, magnetic performance must always be assessed together with the arrangement of the magnets.

Durability of the rubber layer

For intensive use, choose a more durable cover capable of withstanding frequent foot traffic and contact with sharp particles.

Ease of cleaning

For frequent use, it is important that the rubber cover can be removed quickly and captured contaminants can be safely cleaned away.

Can a magnetic mat replace changing shoes?

A mat can reduce the amount of ferromagnetic particles carried on footwear. However, it cannot generally be said that it completely replaces changing shoes, shoe covers or hygienic cleaning in every facility.

The specific requirements of the facility, internal hygiene regulations, risk assessment and auditor requirements are decisive.

Is a magnetic mat suitable for food-processing facilities?

It can form part of a transition system between the technical and food-production areas of a facility. However, it is necessary to verify:

• suitability of the materials for the specific environment,
• possibility of hygienic cleaning,
• resistance to the cleaning agents used,
• requirements of the internal HACCP system,
• auditor requirements,
• risk of cross-contamination,
• placement within the overall hygiene system.

A magnetic mat is not a disinfection device and does not provide microbiological cleanliness of footwear on its own.

Safety when using magnetic mats

Recommended magnetic mats

The selected products represent three different options: a more robust UP version, a compact Standard mat and a larger mat providing a longer transition area.

Frequently asked questions about magnetic industrial mats

Summary

A magnetic industrial mat helps reduce the transfer of ferromagnetic contaminants from workshops, metalworking and technical areas into cleaner parts of a facility.

Powerful neodymium magnets positioned beneath the rubber layer attract steel shavings, filings, small metal fragments and other magnetic particles from the soles of work shoes.

The mat does not capture aluminium, copper, plastic, sand or other non-magnetic contaminants. It therefore does not replace conventional shoe cleaning, changing footwear or disinfection measures where these are required.

When selecting a mat, consider the size of the passageway, number of employees, amount of contamination, mat weight, durability of the rubber cover and ease of cleaning. Always verify its effectiveness under real operating conditions at the specific facility.