Armor Ball® — Industrial-Grade Shade Balls for Evaporation, Algae & Odor Control
Armor Ball® is AWTT's industrial-grade floating ball cover — the engineered evolution of basic shade balls for reservoirs and ponds. Made of UV-stabilized hollow HDPE spheres (100 mm / 4-inch diameter), Armor Ball® self-interlocks to achieve 91% surface coverage, reducing evaporation by up to 90%, eliminating algae, and suppressing odors. Rated for 25+ years and backed by a 10-year warranty.
91%
Surface Coverage
90%
Evap. Reduction
25+
Year Lifespan
$
Lowest Cost
The Problem: Uncovered Industrial Ponds Cost Millions
Every open industrial lagoon, evaporation pond, wastewater basin, or process water storage tank is continuously losing water, releasing odors, growing algae, and attracting wildlife. In arid or semi-arid regions, an uncovered 5-acre pond can lose over 1 million gallons per year to evaporation alone — water that must be replaced at significant cost.
Algae growth degrades treatment performance, creates cyanotoxin risk, and drives up chemical consumption. Odor and VOC emissions trigger regulatory complaints and compliance risk. Wildlife access contaminates process water. These are compounding operational liabilities.
The Solution: Armor Ball® — Deploy in Hours, Protect for Decades
Armor Ball® floating covers are engineered to eliminate these problems in a single, simple deployment. Thousands of hollow HDPE spheres (100mm / 4-inch diameter) are poured directly onto the liquid surface. They self-arrange into a dense, interlocking layer that achieves 91% surface coverage immediately — blocking sunlight, reducing air-to-liquid contact, and creating a physical barrier against wildlife.
No anchors, no pumps, no structural modifications to the pond. As liquid levels rise and fall, the Armor Ball® cover floats continuously at the surface. It works in any pond geometry — round, rectangular, or irregular — and requires no maintenance for its 25+ year service life.
Armor Ball® Technical Specifications
Full specification data for engineering evaluation, procurement, and compliance documentation.
| Surface Coverage | 91% |
| Ball Diameter | 100 mm (4 inches) |
| Ball Weight (dry) | 50 g |
| Density | 10 balls/ft² (108 balls/m²) |
| Buoyancy | 10.9 lb/ft² (53 kg/m²) |
| Wind Resistance | 35 MPH (56 km/h) |
| Evaporation Reduction | Up to 90% |
| Heating Cost Reduction | Up to 70% |
| Operating Temperature | −70°F to +160°F (−57°C to +71°C) |
| Material | UV-stabilized HDPE |
| Life Expectancy | 25+ years |
| Warranty | 10 years (manufacturer) |
| Maintenance | None required |
| Installation | Tool-free — simply fill the pond surface |
| Chemical Resistance | Excellent — inert to most industrial liquids |
Key Benefits of Armor Ball® Floating Covers
Six operational and environmental advantages from the most widely deployed product in AWTT's 700+ installation, 25-country portfolio.
Up to 90% Evaporation Reduction
Hollow HDPE spheres form a tight interlocking layer that breaks surface tension and dramatically reduces water loss from evaporation.
Algae & Cyanobacteria Suppression
Blocks sunlight penetration to effectively halt algae and cyanobacteria growth without chemicals or ongoing maintenance.
Odor & VOC Control
The ball cover layer acts as a physical barrier, reducing hydrogen sulfide and VOC emissions from wastewater and industrial liquid storage.
Bird & Wildlife Deterrent
The unstable rolling surface prevents waterfowl, deer, and other wildlife from landing or accessing the liquid surface.
Snow, Ice & Chemical Resistant
Maintains performance at −70°F. UV-stabilized HDPE resists all common industrial chemicals, acids, and biological agents.
Tool-Free Installation
No pumps, anchors, or structural modifications required. Pour balls onto the surface — installation is complete in hours, not days.
Armor Ball® Applications
Proven in sheltered to moderately exposed industrial liquid containment environments across North America.
Dairy & Agricultural Lagoons
Odor suppression and ammonia emission reduction for CAFO compliance.
Biogas Digester Ponds
Thermal retention for mesophilic and thermophilic anaerobic digesters.
Mining Process Ponds
Evaporation control for heap leach pads, tailings ponds, and process water basins.
Chemical Plant Lagoons
VOC and chemical vapor suppression in industrial liquid containment.
Wastewater Treatment Ponds
Odor and H₂S control for municipal and industrial treatment lagoons.
Water Storage Reservoirs
Municipal and industrial water storage evaporation reduction in drought-prone regions.
Shade Balls vs. Armor Ball® — What's the Difference?
After the Los Angeles reservoir shade ball deployment made worldwide headlines, "shade balls" became a household term. Armor Ball® is the industrial-grade, engineered version of that same concept — purpose-built for demanding commercial and municipal applications.
Basic Shade Balls
- - Thin-wall hollow plastic spheres
- - Primarily UV blocking for algae/chloramine
- - Limited chemical resistance
- - Short lifespan (3-10 years typical)
- - No insulation value
- - No wind resistance rating
Armor Ball® by AWTT
- + UV-stabilized HDPE — industrial chemical resistant (pH 2-13)
- + 91% surface coverage — evaporation, algae, odor, and VOC control
- + 10.9 lb/ft² buoyancy — resists wave action
- + 25+ year engineered lifespan with 10-year warranty
- + R-2 insulation value — reduces heating costs
- + Operates −70°F to +160°F — all climates
Looking for higher wind resistance or insulation? See AWTT's full product range — from 30 MPH to 130+ MPH, R-1 to R-17+.
Verification & documentation
AWTT keeps lab reports and project certificates request-gated, while making technical documentation for Armor Ball available to qualified specifiers.
Request-gated
Certificates, SDS, and test reports
Request material certificates, SDS sheets, wind/UV/R-value reports, and third-party documentation for submittal packages.
Public data
Technical data and comparisons
Review HTML tables, JSON/CSV data, and public specifications for coverage, wind, buoyancy, R-value, and design life.
Frequently Asked Questions
Direct answers for engineering, procurement, and compliance teams evaluating AWTT floating covers.
When should I choose Armor Ball instead of Hexprotect?
How much surface coverage does Armor Ball provide?
Can Armor Ball be installed without draining the pond?
Do AWTT floating covers leach PFAS, BPA, BPS, or BPF into drinking water?
Can AWTT provide lab reports, SDS sheets, and material certifications for submittals?
Engineering Tools & Resources
Evaporation & ROI Calculators
Calculate evaporation losses, estimate surface area, and compare cost savings across cover systems.
Not Sure Which Cover?
Answer a few questions about your site conditions and get a personalized product recommendation.
Technical Specifications
View full engineering specs, wind resistance data, R-values, and material compliance details.
Get an Armor Ball® Quote for Your Pond
Provide your pond dimensions and AWTT's engineering team will deliver a custom coverage estimate, product recommendation, and pricing — typically within 24 hours.