AWTT modular floating pond cover system deployed across a large industrial water storage reservoir demonstrating evaporation control, algae suppression, and odor reduction
Full Product Range

Floating Pond Cover Products — Modular HDPE Covers for Evaporation Control, Algae Prevention & Odor Reduction

Seven engineered floating cover systems for every industrial liquid containment need — from cost-efficient 91% coverage ball covers to R-17+ insulated biogas digester systems. All manufactured from UV-stabilized HDPE in North America. 10-year warranty. 25+ year lifespan.

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AWTT's modular floating pond covers are engineered to solve the most persistent and costly problems of open liquid storage: evaporation loss, algae and cyanobacteria growth, odor and VOC emissions, and thermal energy waste. Manufactured from high-density polyethylene (HDPE) in North America, every AWTT cover system delivers a 25+ year operational lifespan with zero maintenance requirements and a 10-year manufacturer warranty.

The AWTT product range spans three proven cover families — Armor Ball®, Hexprotect®, and Rhombo — each available in configurations optimized for different applications, budgets, and operating environments. Whether the priority is maximum evaporation reduction (up to 95%), thermal insulation for biogas digesters (R-17+, 85% heating cost reduction), extreme wind resistance (130+ MPH), or maximum load-bearing buoyancy (50 lb/ft²), there is an AWTT floating cover engineered for the requirement.

All seven AWTT floating covers share a common set of proven capabilities: odor suppression, chemical evaporation control, algae elimination, bird and wildlife deterrence, snow and ice resistance to –70°F, and tool-free installation without heavy equipment. Modular design allows phased deployment across any pond, reservoir, or lagoon geometry — no structural modification to the containment basin required.

AWTT Floating Cover Product Range

Seven modular HDPE floating cover systems — from economical 91% ball covers to maximum-buoyancy Rhombo industrial panels. All share a 25+ year lifespan and a 10-year warranty.

Armor Ball hollow HDPE sphere floating covers deployed across an industrial water storage pond providing 91% surface coverage for evaporation control, algae suppression, and bird deterrence Most Economical

Armor Ball®

  • 91% Coverage
  • 10.9 lb/ft² Buoyancy
  • 25+ Yr Lifespan

Hollow HDPE spheres delivering 91% surface coverage for cost-efficient evaporation reduction, algae control, and odor suppression. The simplest, lowest-cost entry point for industrial pond protection with low wind exposure.

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Armor Ball AQUA water-ballasted wind-resistant HDPE floating cover spheres on an exposed outdoor industrial process water pond providing 75 MPH wind resistance and 91% surface coverage Wind-Resistant

Armor Ball® AQUA

  • 91% Coverage
  • 5 lb/ft² Buoyancy
  • Wind: 75 MPH

Water-ballasted Armor Ball variant engineered for exposed outdoor ponds with moderate to high wind loading. The water-fill ballast anchors the cover against sustained wind without mechanical fasteners or pond modification.

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Hexprotect SLIM interlocking hexagonal HDPE floating covers on a water storage tank providing 99% surface coverage for economical evaporation reduction and algae prevention 99% Coverage

Hexprotect® SLIM

  • 99% Coverage
  • 1 lb/ft² Buoyancy
  • Most Affordable 99%

Patented hexagonal tile design achieving 99% surface coverage at an economical price. Ideal for water storage tanks and ponds requiring maximum algae suppression and evaporation control without extreme wind or heavy-load demands.

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Hexprotect AQUA interlocking hexagonal HDPE floating covers on a municipal drinking water reservoir providing 99% surface coverage with excellent wind resistance and NSF/ANSI potable water safety compliance Best All-Around

Hexprotect® AQUA

  • 99% Coverage
  • 8 lb/ft² Buoyancy
  • Wind: 130+ MPH

The flagship AWTT hexagonal cover — 99% surface coverage combined with 130+ MPH wind resistance, proven across drinking water reservoirs, industrial ponds, agricultural impoundments, and wastewater treatment facilities. The top-selling AWTT product.

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Hexprotect MAX R insulated floating cover with R-17 closed-cell polyurethane foam insulation layer on a biogas anaerobic digestion lagoon delivering 85% heating cost reduction and 99% surface coverage R-17+ Insulated

Hexprotect® MAX R

  • R-Value: R-17+
  • 99% Coverage
  • 85% Heat Savings

Maximum thermal insulation — R-17+ from 2.5–3" closed-cell polyurethane foam. Reduces biogas digester and heated lagoon operating costs by up to 85%. The engineered choice for anaerobic digestion, biogas production, and any process requiring sustained elevated liquid temperature.

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Rhombo Hexoshield 66 hybrid modular floating cover on a large industrial impoundment providing 25 lb per square foot buoyancy capacity, R-4 insulation, and 99% surface coverage DOE Award Winner

Rhombo Hexoshield® 66

  • 99% Coverage
  • 25 lb/ft² Buoyancy
  • Wind: 130 MPH

Winner of the 2017 U.S. Department of Energy Sustainability Award. Hybrid modular floating cover delivering 25 lb/ft² buoyancy with R-4 insulation and 130 MPH wind resistance (water-ballasted). Saved 55 million gallons/year at the Savannah River Site.

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Rhombo Hexoshield 189 heavy-duty modular floating cover on a large industrial liquid containment basin providing 50 lb per square foot buoyancy capacity, 90+ MPH wind resistance, and 99% surface coverage Max Buoyancy

Rhombo Hexoshield® 189

  • 99% Coverage
  • 50 lb/ft² Buoyancy
  • Wind: 90+ MPH

The highest-buoyancy cover in the AWTT range at 50 lb/ft² — engineered for the most demanding industrial containment environments. 90+ MPH wind resistance, R-8 insulation, and up to 98% evaporation reduction with structural capacity for equipment access, snow loads, and accumulated solids.

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Products Comparison

Side-by-side specification comparison across all seven AWTT floating cover products. Scroll horizontally on smaller screens.

Products Comparison Armor Ball® Armor Ball® AQUA Hexprotect® SLIM Hexprotect® AQUA Hexprotect® MAX R Rhombo Hexoshield® 66 Rhombo Hexoshield® 189
Surface Coverage 91% 91% 99% 99% 99% 99% 99%
Insulation (R Factor) R-2 R-1 R-1 R-2 R-17+ R-4 R-8
Heating Cost Reduction 70% 75% 70% 85% 90% 75% 80%
Evaporation Reduction 90% 90% 95% 95% 97% 98% 98%
Wind Resistance 35 MPH 75 MPH 30 MPH 130+ MPH 40 MPH 130 MPH 90+ MPH
Buoyancy (lb/ft²) 10.9 5 1 8 16 25 50
Odor Control
Chemical Evap. Control
Algae Reduction
Bird Deterrent
Snow & Ice Resistant
Quick Install
Maintenance Free
Life Expectancy 25+ Years 25+ Years 25+ Years 25+ Years 25+ Years 25+ Years 25+ Years
Cost Tier Lowest Moderate Moderate Lowest Highest Moderate High
Lowest to Highest Relative installed cost tier for budgetary comparison Standard feature included on all models

Frequently Asked Questions

Common questions from engineers and procurement teams evaluating AWTT floating cover systems.

What is the difference between Armor Ball® and Hexprotect® floating covers?
Armor Ball® covers are hollow HDPE spheres that achieve 91% surface coverage and provide reliable evaporation reduction and algae control at the lowest cost per acre. Hexprotect® covers use an interlocking hexagonal tile design that achieves up to 99% surface coverage — providing higher evaporation reduction, better wind resistance, and superior algae control for applications requiring maximum performance.

Which AWTT floating cover provides the best insulation for biogas and heated lagoon applications?
The Hexprotect® MAX R provides the highest insulation performance with an R-value of 17 or greater through a 2.5–3" closed-cell polyurethane foam insulation layer. This enables up to 85% reduction in heating costs for anaerobic digestion lagoons, biogas plants, and industrial processes that require sustained elevated liquid temperatures.

Which AWTT floating cover is best for high-wind exposed pond sites?
The Hexprotect® AQUA and Rhombo Hexoshield® 66 provide the highest wind resistance in the AWTT range at 130+ MPH through water ballast systems. The Rhombo Hexoshield® 189 achieves 90+ MPH and the Armor Ball® AQUA resists winds up to 75 MPH — all without mechanical anchoring or pond modification.

What buoyancy capacity do AWTT floating covers provide?
AWTT floating cover buoyancy ranges from 1 lb/ft² (Hexprotect® SLIM) to 50 lb/ft² (Rhombo Hexoshield® 189). For heavy industrial applications requiring equipment access, snow load capacity, or accumulated solids management, the Rhombo Hexoshield® 189 provides the highest buoyancy. For standard water storage ponds and reservoirs, the Armor Ball® at 10.9 lb/ft² and Hexprotect® AQUA at 8 lb/ft² provide ample performance.

How long do AWTT floating covers last?
All AWTT floating cover products are manufactured from UV-stabilized high-density polyethylene (HDPE) with a 25+ year design lifespan and a 10-year manufacturer warranty. HDPE resists UV radiation, chemical exposure, temperature extremes down to –70°F, and biological degradation — supporting long-term performance without maintenance or replacement.

Not Sure Which Cover Is Right for Your Application?

Contact AWTT's engineering team for a custom product recommendation — including site-specific performance estimates, specification sheets, and ROI analysis for your pond, reservoir, or lagoon.

Contact Us Call 1-956-244-6523