In industrial facilities where ferrous loads are handled every day, lifting electromagnets are indispensable tools, always ready to do their job with precision and consistency. Reliable, robust, and designed to work even in challenging conditions, these devices are at their best when given the appropriate care.

With a few simple, targeted checks, it is possible to keep them efficient over time, optimising performance and extending their life. Maintenance does not require complex procedures or costly interventions, just insert specific inspections into the work schedule is enough to ensure operational continuity and safety.

This guide provides all the essential information on what to check, how often, and according to the type of lifting electromagnet in use. It is a practical tool for professionals working with these systems who want to get the most out of each lifting cycle.

Regular maintenance of lifting electromagnets is essential to guarantee operational continuity, device life, and safety during each working cycle. It does not involve invasive interventions but rather well-planned, straightforward, and focused checks.

Even though these devices are built to last, it is regular maintenance that preserves their efficiency over time. In particular, checking the condition of welds and the tightness of the connection box is essential: small cracks or water infiltrations can damage the internal winding. If not detected in time, such issues can lead to extremely costly repairs, up to 50% of the price of a new magnet.

By incorporating a few technical checks into the plant’s daily routine, extraordinary interventions can be avoided, and the electromagnet is always kept performing.

Inspecting seals, monitoring the integrity of the connection box, checking weld conditions: these are quick but fundamental activities. Thanks to these attentions, the electromagnet continues to function efficiently, without drops in performance and without operational interruptions.

Methodically preventing means giving value to your system, extends the life of the magnet, and ensures that every lifting operation is carried out with maximum safety. With proper maintenance, the lifting electromagnet remains a reliable asset, day after day.

There is no universal rule for all situations, routine maintenance of a lifting electromagnet depends on the specific context. What matters is how often, and more importantly, how and where the magnet is used.

In more demanding industrial environments, such as scrap yards, foundries, or steelworks, where contact with abrasive materials is part of daily operations, it is advisable to schedule more frequent inspections. The goal is not to act only when something goes wrong, but to prevent failures altogether. Maintaining consistent performance over time requires a methodical and committed approach.

When properly structured, routine maintenance becomes a seamless part of operational workflows. Here’s a straightforward schedule that can be easily integrated:

Weekly

A quick but crucial check: ensure that the connection between the electromagnet’s plug and the operating machine is secure, intact, and free from signs of wear. It may seem like a small detail, but it makes all the difference.

Monthly

Take a few minutes to inspect the following:

• The lifting chain and pins: they must be intact, with no stretched links or visible deformations.

• The magnet’s frame, especially the bottom section, which is in direct contact with materials: a visual inspection can reveal signs of abrasion or microcracks in the welds.
• The magnetic surface cleaning: removing ferrous residues and dirt helps maintain a consistent and uniform magnetic attraction.

Every year

The time has come for more structured checks:

• Open the cable connection box and check that the clamps are firm and free of oxide. Check the gasket: if it is damaged or no longer guarantees the seal, replace it.
• Check that the identification plate is present and legible: it is the “identity card” of your magnet, essential to trace the model in case of support or spare parts request.
• Have qualified personnel carry out the control and certification of the lifting chain, as required by current regulations.

Two controls to integrate into routine maintenance to ensure greater reliability and prevent any damage, we recommend including two additional controls, specific for hydraulic, battery-powered and combustion engine electromagnets:

• Control of the protective cover

It must always be well fixed to the body of the magnet. A loose, folded, or broken lid can compromise the integrity of the internal components or let in dust, liquids, or debris. An unabsorbed shot is enough to cause invisible but critical damage over time.

• Control of rubber vibration dampers

These elements serve to absorb shocks and mechanical vibrations. They must be inspected monthly and replaced if damaged or hardened. In case of intensive use of the magnet, annual replacement is recommended, even in the absence of visible defects, to ensure effective mechanical protection.

Every day, the bottom of the magnet works closely with scrap, sheet metal, sharp materials and abrasive surfaces. It is the most exposed point, and therefore the most subject to wear. A completely normal consumption, which however must be managed methodically.

When you start to notice deep scratches, signs of abrasion or minor damage in the area in direct contact with loads, it’s time to take action. There is no need to wait until the damage becomes critical: a weld carry out at the right time is an excellent form of prevention.

By using wire or electrode compatible with carbon steels, the original thickness is restored and the surface is strengthened, making it ready to face new work cycles without loss of efficiency.

It is a technical, but quick, operation which, if included among the periodic checks, allows the performance of the magnet to be kept high and its life to be extended decisively, reducing the need for more invasive replacements or interventions.

With routine maintenance done on time, the lifting electromagnet works for a long time without surprises. But like any industrial system, there are situations where it is useful –or necessary – to go beyond routine checks. 

This is not an activity to be programmed regularly, but a resource to be activated only when it is really needed: targeted action in response to specific signals, linked to the type of technology used or more delicate components.

Hydraulic Electromagnets

The hydraulic circuit is one of the system’s vital components and must be monitored carefully. Oil leaks can not only affect performance but must also be addressed immediately to avoid environmental penalties. In some cases, extraordinary maintenance may also involve the system’s electronic components, such as inspecting control boards, capacitors, fuses, or the voltage generator.

Battery-Powered Electromagnets

At the core of these models lies the battery pack. A periodic visual check may be enough, but if you notice damage or accumulated dirt,it is a good idea to intervene to guarantee autonomy and safety. When batteries need to be replaced, disposal must comply with environmental regulations, with attention to traceability. Here too, extraordinary maintenance may involve internal electronic components (boards, fuses).

Diesel/Petrol-Powered Electromagnets

In this case, focus shifts to the power unit. Regular cleaning of the control unit, careful inspection of fuel lines, and ensuring there are no fuel leaks are key to maintaining system reliability and safety, even under heavy use. This configuration may also require extraordinary electronic maintenance.

All Other Electromagnet Types

For all remaining types, the same standard maintenance principles apply: simple yet consistent inspections. If these are respected, the need for extraordinary interventions is reduced to a minimum.

Knowing when and where to intervene, based on the technology used, is the best way to work safely and continuously.

At present, there is no regulation that imposes strict maintenance intervals for lifting electromagnets. However, industry professionals are well aware that safety, traceability, and environmental compliance are not optional, they are essential operational standards.

Even when not explicitly required by law, maintenance is crucial for ensuring compliance with general workplace safety and environmental protection regulations.

Certain aspects must be regularly monitored, regardless of the electromagnet type in use:

Lifting chains

These must be inspected and certified annually by qualified personnel. This well-established practice protects operators and enhances workplace safety.

Electrical connections

The connection between the electromagnet’s plug and the machine must always be secure, intact, and free of oxidation.

Oil or fuel leaks

In systems where hydraulic or combustion engine magnets are used, it is essential to check that there are no spills. This is not just a technical aspect: in case of losses, environmental sanctions can be applied.

Battery disposal

If the magnet is battery powered, each replacement must include controlled and compliant disposal. It is not only an ecological issue, but also one of legal responsibility.

Identification plate

This must always be clearly visible and legible. It includes the serial number and allows for immediate identification of the model and technical configuration in case of maintenance or spare part requests.

Zanetti Magneti designs each electromagnet with the aim of simplifying maintenance and facilitating compliance with regulations, offering robust solutions that are easily inspected and precisely documented. Less unexpected events, more operational continuity.

Do you need support for the maintenance of your electromagnet? Do you want to understand which model is best suited to your operational needs?

Zanetti Magneti is here to support you: from product selection to long-term maintenance, we offer technical expertise, tailored interventions, and ongoing assistance.

Contact us to schedule a maintenance visit or request a personalised consultation with one of our specialists.