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.
Reviewed by AWTT engineering team · Updated March 2026 · All specifications technically verified
Headquarters Harlingen, Texas
Corporate headquarters
- Centralized AWTT quote response
- Engineering and product specification support
- Global manufacturing coordination
Headquarters and manufacturing network
Corporate headquarters plus regional production and logistics
AWTT is headquartered in Harlingen, Texas and supports projects through a manufacturing and logistics network spanning South Carolina, Mexico, Budapest, and Jebel Ali.
Eastern United States, Atlantic Coast, and Southeast projects
South Carolina
Eastern U.S. manufacturing support
South CarolinaMexico, Central America, South America, and cross-border U.S. projects
Mexico
Mexico and Latin America manufacturing support
MexicoEuropean Union, Central Europe, and nearby export markets
Budapest, Hungary
European manufacturing and logistics support
Budapest, HungaryMiddle East, Africa, South Asia, and nearby export markets
Jebel Ali, UAE
Middle East manufacturing and export logistics support
Jebel Ali, UAEEngineered 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®
StandardShell: 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
Armor Ball® AQUA 275
Wind-RatedWind 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
Hexprotect® AQUA
Best CoverageCoverage: 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
Hexprotect® MAX R
InsulatedR-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
Hexprotect® SLIM
Low-ProfilePatent-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
Rhombo Hexoshield®
DOE Award WinnerEvaporation 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
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.
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.
| 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?
What wind speeds can AWTT floating covers withstand?
How much can floating covers reduce evaporation?
What surface coverage percentage do Hexprotect floating covers achieve?
What is the thermal insulation R-value of the Hexprotect MAX R?
How long do AWTT floating covers last and do they require maintenance?
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.
Popular Resources
Engineering guides, comparison tools, and technical references for floating cover specification and procurement.
How to Choose the Right Floating Cover
Selection guide with decision flowchart and product comparison table.
Evaporation Calculator & ROI Tool
Estimate water loss and calculate cost savings with a floating cover system.
Wind Resistance Guide
Which covers survive high winds — rated from 35 MPH to 130+ MPH.
Modular Cover vs. Geomembrane
25-year cost and maintenance comparison of modular vs. solid cover systems.
Technical Data & Specifications
Full specs, filterable comparison table, and test methodology for all products.
Wastewater Lagoon Covers
Odor control, algae prevention, and evaporation reduction for treatment lagoons.
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.