Installation Guide

How AWTT Floating Covers Are Installed

One procedure works for every AWTT modular floating cover — Armor Ball, Hexprotect, and Rhombo. Two people, mesh bags, and the surface of your basin. No anchors, no welding, no pond draining.

Watch: Hexprotect® AQUA installation walkthrough — forklift and bulk-bag deployment (22 s). The same procedure applies to every AWTT modular cover.

One Procedure for Every Modular Cover

Whether the project uses 100 mm Armor Ball spheres, 220 mm Hexprotect AQUA interlocking hexagons, or larger Rhombo Hexoshield panels, the installation procedure is the same: AWTT ships the cover in mesh bags, a two-person crew lifts each bag over the basin and opens it, and the elements fall onto the liquid surface and self-arrange into the coverage pattern. There are no anchors to weld, no perimeter cables to tension, and no pond modification of any kind.

This is possible because every AWTT modular cover is engineered to be hydrodynamically self-arranging — the geometry of each element drives the pattern, not external assembly. Hexprotect AQUA tiles ship pre-loaded with water for ballast (100%–300% of basic tile weight); Armor Ball and Hexprotect SLIM are lightweight and rely on geometry alone; Rhombo Hexoshield panels are heavier and may be placed by forklift. The release-and-self-arrange step is identical across all of them.

Floating baffles are a different product class. They are anchored membrane structures and require a separate installation procedure — not covered on this page. Contact AWTT for baffle installation guidance.

Step-by-Step Procedure

Standard installation procedure for AWTT Armor Ball, Hexprotect, and Rhombo modular floating covers.

  1. Verify your delivery

    Check the bill of lading (BOL) against your order on arrival. Inspect the mesh bags before opening to confirm quantities and condition. Contact AWTT immediately if anything is short or damaged.

  2. Confirm basin openings are smaller than the cover element

    Every intake and outlet on the basin must be smaller than the diameter of the floating cover element (220 mm for Hexprotect AQUA, 100 mm for Armor Ball, etc.). This prevents elements from being drawn into pipes or screens and obstructing flow.

  3. Clear surface debris from the liquid

    Remove any naturally occurring floating debris or thick viscous layers from the surface before deployment. A clean surface lets the cover distribute and self-arrange into the correct uniform pattern.

  4. Stage a two-person crew with fall protection

    The minimum safe crew is two people. The person handling bags over the basin must be secured with fall protection — a harness anchored to the basin edge or a guardrail. AWTT recommends supervision and does not allow walking on the cover at any point.

  5. Release the elements onto the liquid surface

    Each mesh bag is light enough to be lifted by one or two people — typically about 40 lb (18 kg). Position the bag over the basin or at the edge with the opening facing down, loosen the drawstring (or cut the bag open with a sharp knife), and let the elements fall onto the liquid. They will self-arrange into the coverage pattern within minutes. A 53-foot dry van of cover is typically unloaded in 1–2 hours.

  6. Apply only 90% of the cover initially

    Hold back roughly 10% of the cover for a second pass. An exact quantity is required for the correct self-arranging pattern, and it is much easier to add more elements later than to remove an overcrowded surface. Extra parts are typically included with every shipment.

  7. Dry-basin installation (optional)

    The cover can be installed in an empty basin from drop heights up to 6 m (20 ft) without damage — the elements are flexible HDPE and tolerate impact onto concrete. Above 6 m drop height, fill the basin first so the elements land on liquid. Be aware that estimating the correct quantity is harder before the basin is filled.

  8. Top up the final 10% once the pattern has formed

    After a few days the cover has fully self-arranged. Add the remaining 10% only where persistent openings exist. Small gaps at the basin edge are normal and intentional — they are part of the 2–6% uncovered area the system needs to maintain its pattern and are accounted for in coverage ratings.

Crew, Time, Tools & Safety

Plan your installation with the requirements below.

Crew

2 people

Minimum safe crew — one handling bags over the basin, one staging and supporting on the bank.

Unload Time

1–2 hrs

Typical time to unload a 53-foot dry van of cover. Pattern forms on the surface within minutes.

Initial Coverage

90% first

Apply only 90% to start. Add the remaining 10% a few days later, only where persistent openings exist.

Max Dry Drop

6 m (20 ft)

Cover may be installed in an empty basin up to 6 m drop height. Above that, fill the basin first.

Tools you'll need

  • Sharp knife or bag cutter for opening mesh bags
  • Fall-protection harness for the bag handler
  • Forklift, crane, or hand-lift — optional, useful for bulk bag handling and heavier Rhombo panels

Safety requirements

  • The person handling bags over the basin must be secured against falling — harness, guardrail, or both.
  • Confirm every intake/outlet opening is smaller than the cover element diameter.
  • Do not walk on the cover. The cover does not provide buoyancy for foot traffic and is not designed for any foreign-object load.
  • Avoid installing in high winds when possible.

Installation FAQ

Common questions about installing AWTT modular floating covers.

How long does installation take?
A two-person crew typically unloads a 53-foot dry van of cover in 1–2 hours. The elements self-arrange into their coverage pattern within minutes of hitting the water; the only follow-up is a brief top-up of the final 10% a few days later.

Can the cover be installed in an empty basin?
Yes — from drop heights up to 6 m (20 ft). The HDPE elements tolerate impact onto a concrete floor without damage. Above 6 m drop height, fill the basin first so the elements land on liquid. Note that judging the correct quantity is harder before the basin is filled, so extra care with measurement is required.

Why apply only 90% of the cover initially?
An exact quantity is required for the self-arranging pattern to form correctly. Too many elements crowd the surface and prevent the system from settling into its 99% coverage geometry. Adding more elements later is much easier than removing an overcrowded surface — and small edge openings are intentional, not defects.

Do mixers, aerators, or pumps affect the cover during operation?
Yes. Maintain a 1–2 m clearance between any moving equipment (impeller, pump intake) and the cover. Pumps must start from below the surface — never with the intake above the cover — and emptying the basin reduces this clearance, so plan accordingly. Direct contact can damage tiles and create fragments that may foul downstream equipment.

What happens in strong winds during or after installation?
On large basins, strong winds can temporarily overlap tiles at the leeward edge. Once the wind drops the cover self-restores its pattern. Hexprotect AQUA, Armor Ball AQUA, Hexprotect MAX R, and Rhombo Hexoshield are engineered for high-wind sites; for very high winds, ask about ballasted or anchored options. Avoid installing in heavy winds when possible.

Is AWTT supervision required on site?
No — the procedure is straightforward enough that trained site personnel typically handle installation directly. AWTT can provide remote support or on-site supervision on request; we recommend close supervision during the first basin if your crew is new to the system.

Does this procedure apply to Armor Ball, Hexprotect, and Rhombo equally?
Yes for the modular tile and ball covers — Armor Ball, Armor Ball AQUA, Hexprotect SLIM/AQUA/MAX R, and Rhombo Hexoshield 66/189 all install with the same bag-release-and-self-arrange procedure shown in the video. Floating baffles are different: they are anchored membrane structures and require a separate installation procedure — contact AWTT for baffle installation guidance.

Engineering Tools & Resources

Evaporation & ROI Calculators

Calculate evaporation losses, estimate surface area, and compare cost savings across cover systems.

Not Sure Which Cover?

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Technical Specifications

View full engineering specs, wind resistance data, R-values, and material compliance details.

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