Hero product
Armor Ball® — the heaviest-duty hollow plastic ball floating cover
Specifications
Confirmed Armor Ball® specifications
Per AWTT published data. All figures render from a single source-of-truth data file.
| Surface coverage | 91% |
|---|---|
| Ball diameter | 100 mm (4 in) |
| Ball weight (dry) | 50 g |
| Density | 10 balls/ft² (108/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 (virgin or recycled) |
| Chemical resistance | Excellent; inert to most industrial liquids (pH 2–13) |
| Insulation | R-2 |
| Life expectancy | 25+ years |
| Warranty | 10 years (manufacturer) |
| Maintenance | None |
| Installation | Tool-free — pour onto the surface; self-interlocking; self-adjusting |
Benefits
Why specifiers choose Armor Ball®
Up to 90% less evaporation
A dense 91% floating layer chokes off the open water surface, cutting evaporative water loss up to 90% — water and dollars kept in the pond.
Algae & cyanobacteria control
Blocking sunlight at the surface starves photosynthesis, suppressing algae and cyanobacteria blooms without adding chemicals.
Odor & VOC suppression
The cover acts as a physical barrier that suppresses odor, H₂S, and VOC emissions rising off the liquid — easing nuisance and compliance pressure.
Bird & wildlife deterrent
A covered surface deters waterfowl and wildlife, reducing contamination and the cleanup and compliance costs that follow.
R-2 thermal insulation
The floating layer insulates the surface at R-2, cutting heat loss and reducing heating costs up to 70% in temperature-sensitive processes.
Extreme chemical & temperature resistance
UV-stabilized HDPE is inert to most industrial liquids across pH 2–13 and holds up from −70°F to +160°F.
Zero maintenance
Once poured, the cover self-adjusts to changing levels and needs no maintenance — no draining, no servicing.
Tool-free install
No anchors, cables, liners, or heavy equipment. Pour the balls onto the surface and they self-arrange into an interlocking cover.
Materials & compliance
UV-stabilized HDPE, documented on request
Armor Ball® is molded from UV-stabilized HDPE specified for potable-water/food-contact use when required. Material certifications, SDS, and NSF/ANSI 61 documentation where applicable are available on request.
- Blocks UV to control algae and cyanobacteria
- Suppresses odor, H₂S, and VOCs
- Deters waterfowl and wildlife
- Lets rain and snow pass through
- Balls can be pushed aside for equipment access, then re-cover automatically
- Not damaged by ice or snow
- Works in any pond geometry
Installation
Tool-free, in four steps
- 1 Calculate quantity Use the surface area of your pond or tank to determine how many balls you need — about 10 balls per ft² (108/m²).
- 2 Deliver in bulk Balls ship in bulk and unload quickly; no special equipment or site prep is required.
- 3 Pour onto the surface Pour the balls directly onto the open liquid surface. No anchors, cables, liner penetration, or draining needed.
- 4 Self-arranges into 91% cover The balls float and self-interlock into a dense 91% layer that self-adjusts as the liquid level changes.
Comparison
Armor Ball® vs. commodity shade balls
| Attribute | Commodity shade balls | Armor Ball® |
|---|---|---|
| Construction | Thin-walled | Thicker-walled / reinforced HDPE |
| Primary purpose | Block sunlight | Heavy-duty floating cover (evaporation, UV, odor, insulation) |
| Surface coverage | Varies | 91% |
| Buoyancy | Not typically rated | 10.9 lb/ft² (53 kg/m²) |
| Chemical resistance | Limited | Excellent; inert across pH 2–13 |
| Operating temperature | Not typically rated | −70°F to +160°F |
| Insulation | None rated | R-2 |
| Wind rating | Not typically rated | 35 MPH (75 MPH for AQUA) |
| Life expectancy | Often 3–10 years | 25+ years |
| Warranty | Varies / none | 10 years (manufacturer) |
Armor Ball® is the lowest-cost, easiest-to-deploy ball cover for sheltered-to-moderately-exposed sites. AWTT's wider range spans 30 MPH to 130+ MPH wind and R-1 to R-17+ insulation.
FAQ
Armor Ball® questions, answered
What is Armor Ball®?
Armor Ball® is the heaviest-duty hollow plastic ball floating cover — a 100 mm (4 in) UV-stabilized HDPE ball that pours onto an open liquid surface and self-arranges into a dense 91% interlocking cover to cut evaporation, block UV, suppress odor, and insulate.
How many Armor Ball® units do I need?
Armor Ball® covers at about 10 balls per ft² (108 per m²). Multiply your surface area by that density — a 1-acre pond (43,560 ft²) needs roughly 435,600 balls. Use the coverage calculator for an exact figure.
How is Armor Ball® installed?
Installation is tool-free: the balls are poured directly onto the liquid surface, where they self-interlock into a 91% layer that self-adjusts to changing levels. No anchors, cables, liner penetration, or draining are required.
What is Armor Ball® made of, and is it safe for potable water?
Armor Ball® is molded from UV-stabilized HDPE specified for potable-water/food-contact use when required. Material certifications, SDS, and NSF/ANSI 61 documentation where applicable are available on request.
What chemicals and temperatures can Armor Ball® withstand?
Armor Ball® is inert to most industrial liquids across pH 2–13 and operates from −70°F to +160°F (−57°C to +71°C) per AWTT published data.
How does Armor Ball® perform in wind?
Standard Armor Ball® is rated for 35 MPH (56 km/h). For more exposed sites, Armor Ball® AQUA uses self-filling water ballast to reach 75 MPH (120 km/h).
What warranty does Armor Ball® carry?
Armor Ball® has a 25+ year design life and a 10-year manufacturer warranty per AWTT published data.
How does Armor Ball® compare to a geomembrane floating cover?
Armor Ball® pours on with no anchors, cables, or liner penetration and self-adjusts to level changes, while a geomembrane cover is an engineered, anchored, sealed installation. Choose a membrane for gas-tight containment; choose Armor Ball® for evaporation, UV/algae, odor, and insulation with minimal install and maintenance.
Get a custom Armor Ball® quote
Tell us about your site — surface area, liquid, and goals — and we'll size a cover and respond within 24 hours.
Manufactured by AWTT · 700+ installations · 25 countries · 10-year warranty