Floating Covers

Floating Covers for Reservoirs, Ponds, Tanks, and Lagoons

Plastic Fusion Fabricators designs, fabricates, and installs custom floating covers for potable water reservoirs, industrial process tanks, wastewater treatment lagoons, agricultural ponds, and environmental containment applications. Our geomembrane floating cover systems sit directly on the liquid surface — rising and falling with water levels — to control evaporation, prevent algae growth, block contamination, manage odors, retain heat, and protect water quality.

Every floating cover we install is engineered for the specific basin geometry, liquid chemistry, environmental exposure, and operational requirements of your application. We fabricate covers from HDPE, LLDPE, RPP, XR-5, and reinforced polypropylene — selected based on UV exposure, chemical compatibility, temperature range, and expected service life. Our patented design features include lateral float systems for stability, integrated rainwater drainage, access hatches, and perimeter anchoring systems engineered for wind uplift, wave action, and thermal expansion.

With 40+ years in environmental containment and geomembrane installation, Plastic Fusion brings field-proven expertise to every floating cover project — from single municipal reservoirs to multi-basin industrial facilities.

Floating Cover Applications

Reservoir Covers Floating covers for potable water reservoirs, treated water storage, and raw water impoundments. Prevent contamination from airborne debris, bird activity, and algae growth while meeting drinking water regulations.

Pond Covers Floating covers for wastewater polishing ponds, stormwater retention, agricultural irrigation ponds, and industrial process water. Control evaporation, prevent algae, and protect water quality.

Tank Covers Floating covers for concrete and steel tanks — process water, equalization tanks, and industrial storage. Custom-fabricated to match your tank diameter and penetration layout.

Heat Retention Covers Insulated floating covers that maintain basin temperatures for anaerobic digestion, biological treatment processes, and temperature-sensitive industrial applications. Reduce heating energy costs and improve biological process efficiency.

Evaporation Mitigation Covers Floating covers engineered to reduce water loss from reservoirs, storage ponds, and industrial basins in arid and water-scarce regions. Documented evaporation reduction rates of 95%+ compared to uncovered surfaces.

Odor Control Covers Gas-tight floating covers that contain odors from wastewater treatment lagoons, industrial process basins, and agricultural waste ponds. Prevent H₂S, ammonia, and VOC emissions from reaching neighboring communities and triggering air quality violations.

Protective Geomembrane Covers Floating geomembrane covers that protect water quality from UV degradation, algae growth, and airborne contamination. Suitable for treated water, process water, and environmental applications.

Biogas Collection Covers Gas-tight floating covers designed specifically for methane capture and biogas collection from anaerobic digesters and covered lagoons. Integrated with gas piping, condensate management, and flare or RNG system tie-ins.

What We Deliver on Every Floating Cover Project

• Custom-fabricated geomembrane covers matched to your basin geometry — no off-the-shelf sizing
• Lateral float systems for cover stability across the full liquid range
• Integrated rainwater drainage to prevent ponding and cover loading
• Perimeter anchoring designed for wind uplift, thermal expansion, and wave action
• Access hatches for sampling, inspection, and maintenance
• Pipe penetrations, instrumentation pass-throughs, and vent assemblies
• In-house HDPE fabrication for cover components, ballast systems, and drainage details
• Full QA/QC documentation — seam testing, material certifications, and as-built records
• Nationwide mobilization with experienced floating cover installation crews

Why Engineers and Facility Owners Specify Plastic Fusion

• 40+ years designing and installing floating cover systems — not a reseller or broker
• Certified thermoplastic welders trained in HDPE, LLDPE, RPP, XR-5, and polypropylene
• Patented floating cover design with proven lateral float and anchoring systems
• In-house fabrication for covers, floats, drainage, and custom components
• Experience across every application: potable water, wastewater, industrial, agricultural, and biogas
• Direct coordination with engineers, facility operators, and regulatory agencies
• Repair and maintenance services for existing floating cover systems
• Management, project, and field superintendent teams with 400+ years combined experience

Industries Served

Plastic Fusion installs floating cover systems for municipal water utilities, wastewater treatment districts, agricultural operations, food and beverage processors, industrial manufacturers, power generation facilities, mining and mineral processing, petroleum refineries, and renewable energy developers. We work under EPA, state drinking water, air quality, and environmental containment regulations.

Floating Cover FAQs

What is a floating cover?

A floating cover is an engineered geomembrane barrier that sits directly on the surface of a liquid in a reservoir, pond, tank, or lagoon. Unlike fixed or rigid covers, floating covers rise and fall with changing liquid levels, maintaining constant contact with the water surface. They’re used to prevent evaporation, block contamination and algae growth, retain heat, capture biogas, and control odors — depending on the application. Floating covers are fabricated from HDPE, LLDPE, RPP, XR-5, or reinforced polypropylene, and include lateral float systems, rainwater drainage, and perimeter anchoring engineered for the specific basin.

What types of floating covers does Plastic Fusion install?

We install floating covers for every major application: reservoir covers for potable water protection, evaporation mitigation covers for water conservation, heat retention covers for digester and process temperature management, odor control covers for wastewater and industrial lagoons, tank covers for concrete and steel vessels, and biogas collection covers for methane capture and renewable energy recovery.

How do floating covers control evaporation?

A floating cover blocks the air-water interface where evaporation occurs. By eliminating wind exposure and direct solar heating of the water surface, a properly installed geomembrane floating cover reduces evaporation by 95% or more compared to an uncovered basin. For reservoirs and industrial ponds in arid climates, that translates to millions of gallons of water conserved annually. The cover also prevents airborne contamination and algae growth, maintaining water quality while reducing loss.

How long do floating covers last?

A properly installed floating cover typically delivers 20–30+ years of service life. Longevity depends on UV exposure intensity, chemical exposure, mechanical stress (wind, wave action, thermal cycling), and the quality of the original seam welding. HDPE and XR-5 covers provide the longest service life in exposed UV conditions. PFF’s QA/QC protocols — including destructive seam testing and full documentation — maximize the installed lifespan of every cover system.

Can floating covers be installed on ponds and lagoons that are already full?

Yes. Floating covers are designed to be deployed on full basins. The cover is fabricated to the basin dimensions, transported to site, unfolded across the liquid surface, and anchored at the perimeter. No draining required. Plastic Fusion’s crews have installed floating covers on operating reservoirs, active wastewater treatment lagoons, and full industrial basins — coordinating with facility operations to maintain production during installation.

What is the difference between a floating cover and a biogas collection cover?

A standard floating cover provides physical barrier functions — evaporation control, contamination prevention, heat retention, or algae suppression. A biogas collection cover adds gas-tight containment and an integrated gas collection system — header piping, condensate management, pressure control, and tie-ins to flare or energy recovery equipment. Biogas covers are a specialized subset of floating covers engineered specifically for methane capture from anaerobic digestion systems.

Request a Quote

Whether you need a floating cover for evaporation control, water quality protection, odor containment, heat retention, or biogas capture, Plastic Fusion designs and installs custom systems matched to your basin and your application. Contact us for project-specific pricing, material recommendations, and mobilization timelines.