Aerial view of a large industrial water reservoir fully covered by AWTT Hexprotect modular floating cover tiles, eliminating evaporation and blocking algae growth
Industrial Water Treatment

Floating Cover Systems for Evaporation Control, Algae Elimination & Odor Reduction

AWTT's modular Armor Ball® and Hexprotect® floating covers protect industrial water storage tanks, reservoirs, and ponds — with over 700 installations across 25 countries and 20M+ sq ft deployed. Reducing evaporation by up to 98%, blocking algae, and suppressing odors through a North American-rooted global manufacturing network with a 10-year warranty.

700+Installations Worldwide
25Countries Served
20M+ ft²Cover Deployed
320+Customers
20+ YearsSince Founded (2004)

Reviewed by AWTT engineering team · Updated March 2026 · All specifications technically verified

Engineered Modular Floating Cover Systems

AWTT's advanced modular floating cover systems are engineered to meet a diverse range of industrial liquid containment needs — including algae suppression, evaporation reduction, odor mitigation, bird deterrence, and water protection. With over 700 installations across 25 countries and more than 20 million square feet of modular cover deployed, AWTT delivers up to 99% surface coverage through patented and patent-pending designs that outperform traditional solid covers in both durability and adaptability. Each cover is uniquely engineered to permit the natural passage of rain and snowmelt into the water body below, without compromising structural integrity or coverage performance — and requires zero maintenance once deployed.

Our floating cover solutions have been adopted across Drinking Water, Wastewater, Industrial Water Storage, Agriculture, Oil & Gas, Biogas, Dairies, Mining, and beyond. AWTT has been instrumental in transitioning operators from traditional sump-style floating covers to versatile, modular designs — introducing patented and patent-pending solutions for Frac Ponds, Above Ground Storage Tanks, Clarifiers, and Insulated Anaerobic Digestion reservoir covers, setting new performance standards across the industry.

Constructed from durable polyethylene and available with either water ballast or closed-cell polyurethane foam insulation, AWTT floating covers are engineered to withstand extreme operating conditions — remaining frost-resistant down to –70°F and wind-resistant against gusts up to 130 MPH. The Hexprotect® AQUA fortress floating cover features an optimized geometry for increased efficiency in shipping and installation, requiring no special tools for deployment. Insulated floating cover models achieve an R-value of 17 through 2.5–3" of insulation and a heat-absorbing black polyethylene shell. AWTT supports projects through regional manufacturing and logistics coverage in North America, Latin America, Europe, and the Middle East — a commitment to quality, durability, and customer-focused engineering.

Armor Ball modular hollow-plastic floating ball covers deployed on an industrial water storage pond for evaporation and algae control

Armor Ball®

Standard

Shell: 1/16″ – 1/8″ thick

Cost-Effective Ball Cover for Standard Applications

  • Hollow HDPE ball construction
  • Easy drop-in deployment
  • Maintenance-free operation
  • Cost-efficient water coverage
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Armor Ball AQUA 275 water-filled wind-resistant floating covers on a large open frac pond, engineered to withstand wind speeds up to 75 MPH

Armor Ball® AQUA 275

Wind-Rated

Wind resistance: 75 MPH

Wind-Resistant Water-Filled Cover to 75 MPH

  • Withstands 75 MPH winds
  • Water-filled ballast anchoring
  • Algae, odor & evaporation control
  • Ideal for frac ponds & exposed reservoirs
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Hexprotect AQUA interlocking hexagonal floating cover tiles achieving 99% coverage on a drinking water reservoir, preventing algae growth and evaporation loss

Hexprotect® AQUA

Best Coverage

Coverage: up to 99%

Hexagonal Tile System with Up to 99% Surface Coverage

  • Up to 99% surface coverage
  • Interlocking hexagonal tile design
  • UV light & algae barrier
  • 130+ MPH self-loading wind resistance
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Hexprotect MAX R insulated floating cover system with 2.5-inch closed-cell foam insulation layer, designed for biogas digesters, dairy lagoons, and cold-climate industrial ponds

Hexprotect® MAX R

Insulated

R-Value: ≥17 | –70°F frost

Insulated Cover: R-Value 17+ and Frost Resistance to –70°F

  • R-value 17+ thermal insulation
  • Frost resistant to –70°F (–65°C)
  • 2.5″–3″ closed-cell insulation
  • Biogas, dairy & cold-climate rated
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Hexprotect SLIM low-profile patent-protected floating cover installed on a wastewater treatment lagoon, providing wind-resistant surface coverage with reduced material profile

Hexprotect® SLIM

Low-Profile

Patent-protected design

Low-Profile Patent-Protected Wind-Resistant Cover

  • Patent-protected geometry
  • Low-profile for minimal wave action
  • Wind-resistant at reduced cost
  • Suitable for all liquid containment
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Rhombo Hexoshield hybrid rhombus-hexagon modular floating cover system on a large industrial chemical storage reservoir, achieving 98% evaporation reduction

Rhombo Hexoshield®

DOE Award Winner

Evaporation reduction: 98%

Hybrid System with Up to 98% Evaporation Reduction

  • Up to 98% evaporation reduction
  • 2017 DOE Sustainability Award winner
  • 130 MPH wind resistance (water-ballasted)
  • Chemical-resistant HDPE construction
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What Sets AWTT Apart

Many companies sell modular floating covers. AWTT is the only manufacturer that designs, engineers, and produces them on proprietary equipment — with independently verified material safety, real wind-tunnel testing, and a 10-year warranty backed by 20+ years in business.

Independently Tested, Certified-Safe Material

We are one of the very few floating cover manufacturers to independently test our recycled plastic content to verify it is free of Bisphenols (BPA, BPS, BPF), Phthalates, and PFAS (Per- and Polyfluoroalkyl Substances).

We use exclusively HDPE (High-Density Polyethylene) — the same food-safe plastic used to manufacture food containers and drinking water pipes. Whether your application is a drinking water reservoir or an industrial lagoon, AWTT covers will not leach harmful chemicals into the environment.

Premium U.S.-Sourced Resin

AWTT purchases raw material from the top-tier resin producers in the United States. Our virgin HDPE is considered the highest-grade available worldwide — the same resin grade used in food and beverage packaging.

We offer both virgin and recycled content depending on customer requirements, but we never compromise on source quality. Every AWTT cover is food-safe, drinking-water-compatible, and environmentally inert — regardless of the application.

A Real 10-Year Warranty — With Spares

AWTT has been in business for over 20 years. Our 10-year warranty is not a marketing claim — it is a commitment we have honored since inception. We also include spare covers with every order, something no other manufacturer offers.

Be cautious of competitors who advertise similar lifespans while using significantly less material and cheaper resin. A thinner cover made from lower-grade plastic cannot physically deliver the same longevity — regardless of what the sales sheet claims.

DOE Award-Winning Original Designs

AWTT is the only floating cover company ever recognized by the U.S. Department of Energy — receiving a 2017 Sustainability Award for our Rhombo cover at the Savannah River Site, which saved 55 million gallons of water per year.

While many of our patented designs have been copied by competitors, AWTT is the original creator of the self-ballasting hexagonal floating cover and most modular cover formats in use today. Copies may look similar on the outside, but they do not match our attention to engineering detail or material quality.

Proprietary Manufacturing Equipment

AWTT is the only company in the world that designs its floating covers in-house and manufactures them on custom-built, purpose-designed equipment used exclusively for producing floating covers — nothing else.

Every competitor we are aware of manufactures on generic injection molding or blow molding equipment shared with other household and industrial products. Generic equipment cannot match the precision, wall thickness consistency, and material distribution that purpose-built tooling delivers. This investment is costly — but it is why AWTT covers outlast the competition.

Wind-Tested — and Hurricane-Proven

Wind resistance is the most critical performance factor for any modular floating cover. Insufficient wind resistance causes covers to stack, pile up, and leave large areas of the liquid surface exposed — defeating the purpose of the installation entirely.

AWTT has invested considerable time and capital in controlled wind testing and outdoor field validation. Our published wind ratings — from 35 MPH to 130+ MPH — are verified through physical testing at scale.

Our Hexprotect® AQUA and Rhombo Hexoshield® covers have survived four named hurricanes — Florence (2018), Dorian (2019), Nicole (2022), and Helene (2024, Category 4) — with zero damage and zero repairs. All covers remain in active service today. They are the only modular floating covers known to have survived hurricane-force conditions.

How Much Water Are You Losing to Evaporation?

Use our free engineering calculators to estimate evaporation losses on your pond or reservoir and calculate ROI for a floating cover system.

Industries We Serve

AWTT modular floating cover systems are deployed across liquid containment applications in more than a dozen industries worldwide — from municipal drinking water to oil field frac ponds.

Drinking Water Reservoirs
Wastewater Treatment
Oil & Gas / Frac Ponds
Biogas & Anaerobic Digestion
Dairies & Agriculture
Chemical Storage
Cement & Mining
Airports & Deicing Ponds
Industrial Water Storage
Slurry & Tailings Ponds
Aquaculture
Power Generation
Overhead photograph of AWTT floating cover system fully installed on a large open-air industrial water storage pond, demonstrating complete surface coverage for evaporation control and algae prevention

Proven Performance Specifications

AWTT floating covers are engineered and tested to measurable performance standards. The metrics below are the key data points engineers, procurement managers, and project developers need for capital project evaluation and specification documents.

130+ MPH
Wind Resistance
Hexprotect® AQUA
Up to 99%
Surface Coverage
Hexprotect® AQUA
Up to 98%
Evaporation Reduction
Rhombo Hexoshield®
R-17+
Thermal R-Value
Hexprotect® MAX R
–70°F
Frost Resistance
All AWTT products
10 Years
Product Warranty
All AWTT products
1/16″ – 1/8″
Shell Thickness
HDPE construction
2.5″ – 3″
Insulation Depth
Hexprotect® MAX R
Table 1: AWTT Floating Cover Product Line — Performance Comparison
Product Wind Resistance Coverage Evap. Reduction R-Value Frost Resistance
Armor Ball® 35 MPH 91% Up to 90% R-2 –70°F
Armor Ball® AQUA 275 75 MPH 91% Up to 90% R-1 –70°F
Hexprotect® AQUA 130+ MPH Up to 99% Up to 95% R-2 –70°F
Hexprotect® SLIM 30 MPH Up to 99% Up to 95% R-1 –70°F
Hexprotect® MAX R 40 MPH Up to 99% Up to 98% R-17+ –70°F
Rhombo Hexoshield® 66 130 MPH 99% Up to 98% R-4 –70°F
Rhombo Hexoshield® 189 90+ MPH 99% Up to 98% R-8 –70°F

Frequently Asked Questions

Common questions from engineers, procurement managers, and project developers evaluating industrial floating cover systems for water storage, wastewater, oil & gas, and agricultural applications.

What is a modular floating cover and how does it work?

A modular floating cover consists of individual interlocking units — hollow balls, hexagonal tiles, or hybrid rhombus modules — that float directly on the surface of water storage tanks, reservoirs, and ponds. The units lock together to create a near-continuous barrier that reduces evaporation by up to 98%, blocks UV light to prevent algae growth, and eliminates odor emissions — all without pumps, sensors, or mechanical components. As water levels change, the floating modules automatically self-level to maintain full coverage.

What wind speeds can AWTT floating covers withstand?

AWTT offers floating covers rated from 30 MPH to 130+ MPH. Product-by-product: Hexprotect® AQUA — 130+ MPH (self-loading), Rhombo Hexoshield® 66 — 130 MPH (water-ballasted), Rhombo Hexoshield® 189 — 90+ MPH, Armor Ball® AQUA 275 — 75 MPH, Hexprotect® MAX R — 40 MPH, Armor Ball® — 35 MPH, and Hexprotect® SLIM — 30 MPH. Wind resistance is verified through controlled wind testing — no mechanical fasteners or perimeter anchoring required.

How much can floating covers reduce evaporation?

AWTT's Rhombo Hexoshield® hybrid system reduces evaporation by up to 98%, while Hexprotect® AQUA and Armor Ball® systems typically reduce evaporation by 90–95% depending on climate and cover density. Uncovered industrial reservoirs in arid regions can lose 50–80 inches of water annually to evaporation — floating covers deliver measurable ROI through water savings alone.

What surface coverage percentage do Hexprotect floating covers achieve?

The Hexprotect® AQUA and related hexagonal tile systems achieve up to 99% surface coverage due to their interlocking geometric design. This near-complete coverage is critical for algae prevention in drinking water reservoirs, odor suppression at wastewater treatment facilities, and UV exclusion in chemical and industrial storage tanks.

What is the thermal insulation R-value of the Hexprotect MAX R?

The Hexprotect® MAX R insulated floating cover achieves an R-value of 17 or greater, with a closed-cell insulation layer 2.5 to 3 inches thick. The outer shell is frost-resistant to –70°F (–65°C), making it ideal for anaerobic digestion tanks, biogas production ponds, dairy lagoons, and industrial chemical storage in cold climates.

How long do AWTT floating covers last and do they require maintenance?

AWTT floating covers carry a 10-year product warranty and are engineered to be 100% maintenance-free. HDPE construction resists UV degradation, chemical corrosion, and biological fouling — no pumps, sensors, or mechanical components required. AWTT supports projects through a North American-rooted global manufacturing network with regional production and logistics coverage.

What Are AWTT Floating Covers Used For?

AWTT modular floating covers are engineered pond covers, reservoir covers, and floating tank covers used to reduce evaporation, block algae growth, suppress odors and VOC emissions, improve thermal retention, and deter wildlife from stored water or process liquids. They are deployed as evaporation control covers on industrial ponds, lagoons, and tanks across drinking water, wastewater, mining, oil & gas, biogas, agriculture, and chemical processing applications. All AWTT modular floating cover systems are made from UV-stabilized, food-safe HDPE — requiring zero maintenance for their 25+ year lifespan.

Ready to Reduce Evaporation Losses and Protect Your Water Supply?

Contact our engineering team for a custom floating cover recommendation, detailed site assessment, or product specification sheet. Serving industrial clients across North America.