Floating Tank Covers

Floating Tank Covers

Plastic Fusion Fabricators designs and installs floating tank covers for industrial process tanks, water storage tanks, wastewater equalization tanks, and chemical storage vessels. Our custom-fabricated geomembrane covers rest directly on the liquid surface — rising and falling with tank levels — to reduce evaporation, control odors and emissions, prevent algae growth, and eliminate the contamination that open tanks are exposed to.

A floating tank cover is a cost-effective alternative to fixed roofs, concrete vaults, and aluminum dome covers. Instead of building a structural roof over the tank, a floating geomembrane cover provides full surface coverage at a fraction of the cost — sealing the liquid surface against evaporation, vapor emissions, and airborne contamination while accommodating the changing liquid levels that process and storage tanks experience.

Plastic Fusion fabricates floating tank covers from HDPE, polypropylene, and reinforced geomembranes — selected for the stored liquid’s chemistry, temperature, and emission profile. With 40+ years in floating cover and environmental containment installation, we deliver tank cover systems engineered for your vessel and built for decades of service.

Applications

• Industrial process water tank covers
• Wastewater equalization (EQ) tank covers
• Chemical storage tank covers
• Water storage and treatment tank covers
• Sludge holding tank covers
• Cooling water basin and tank covers
• Odor control for emission-generating tanks
• Heat retention for temperature-sensitive tank processes
• Biogas capture from anaerobic process tanks

Why Floating Covers vs. Fixed Tank Roofs

Floating geomembrane tank covers offer significant advantages over fixed structural covers:

• Lower installed cost — a fraction of the cost of aluminum domes, concrete vaults, or structural steel roofs
• No structural loading — the cover floats on the liquid, requiring no support columns or load-bearing tank modifications
• Variable level accommodation — the cover rises and falls with the liquid, maintaining surface contact at any tank level
• Emission and evaporation control — full surface coverage seals vapors and reduces evaporative loss
• Simplified installation — no crane lifts or extended tank outages for structural erection
• Corrosion immunity — geomembrane materials don’t corrode in the vapor environment that attacks steel and aluminum covers

Why Engineers and Facility Owners Specify Plastic Fusion

• 40+ years installing floating cover systems
• Custom fabrication to any tank diameter and configuration
• Material selection matched to stored liquid chemistry and temperature
• Certified thermoplastic welders with full QA/QC seam testing
• Lateral float systems, rainwater drainage, and access hatches integrated into every cover
• In-house HDPE fabrication for cover components and tank penetrations
• Covers deployed on full, active tanks without draining
• Nationwide mobilization with experienced floating cover crews

Floating Tank Cover FAQs

What is a floating tank cover?

A floating tank cover is a geomembrane barrier that rests directly on the liquid surface inside a storage or process tank, rising and falling with the liquid level. It provides full surface coverage to reduce evaporation, contain vapor emissions and odors, prevent algae growth, and block airborne contamination. Industrial floating tank covers are custom-fabricated from HDPE or reinforced polypropylene and engineered for the specific tank dimensions and stored liquid — unlike consumer drop-in lids or floating balls, these are engineered containment systems built for industrial service.

What is the difference between a floating tank cover and a fixed roof?

A fixed roof — aluminum dome, concrete vault, or structural steel — is a permanent structure built over the tank, requiring support systems and significant capital cost. A floating tank cover rests on the liquid surface itself, requiring no structural support and costing a fraction of a fixed roof. Floating covers also automatically accommodate changing liquid levels, maintaining full surface coverage whether the tank is full or drawn down. For evaporation control, emission containment, and odor management, a floating cover delivers the same surface seal as a fixed roof at much lower cost.

What tanks can be fitted with floating covers?

Floating covers work on virtually any open-top tank — industrial process tanks, wastewater equalization tanks, water storage tanks, chemical storage vessels, sludge holding tanks, and cooling basins. The cover is custom-fabricated to the tank’s interior dimensions and deployed on the liquid surface. Tank diameter, liquid level fluctuation range, and stored liquid chemistry determine the material and cover design.

How long do floating tank covers last?

Properly installed HDPE and reinforced polypropylene floating tank covers typically deliver 20–30+ years of service life. Longevity depends on the stored liquid’s chemistry, temperature, UV exposure (for outdoor tanks), and seam welding quality. Plastic Fusion selects cover materials matched to your tank’s specific conditions to maximize service life.

Request a Quote

If you need a floating cover for an industrial process tank, water storage tank, or chemical storage vessel, Plastic Fusion designs and installs custom systems engineered for your tank and your application. Contact us for project-specific pricing, material recommendations, and installation timelines.