Product information

Hexa-Cover® floating cover tiles: how they work, sizes and specifications

Solid hexagonal tiles that float on the liquid and arrange themselves into a closed cover. For tanks, ponds, lagoons and reservoirs of any shape, in water, wastewater and industrial liquids.

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What Hexa-Cover® is

Hexa-Cover® is a patented floating cover made of individual hexagonal tiles. Each tile is moulded from recycled polypropylene and has ribs on both sides. Poured onto a liquid, the tiles spread out and settle edge to edge, covering up to 99% of the surface.

Because the cover is made of loose tiles and not one sheet, it fits round tanks, rectangular basins and irregular ponds equally well, rises and falls with the liquid level, and can be made larger or smaller by adding or removing tiles.

It has been on the market since 2004 and is manufactured by Hexa-Cover A/S of Denmark, with production in the EU, North America and Australia.

What it does

Up to 95%

less odour. For sewage, industrial wastewater, leachate and slurry.

Up to 95%

less emission, such as ammonia from the liquid surface.

Up to 95%

less evaporation from stored water.

Up to 99%

less algae and organic growth, because sunlight no longer reaches the water.

74%

lower heat flux than an open surface, measured by Aalborg University on R114.

Birds stay off

The small tiles deter waterfowl from landing on the covered liquid.

“Up to” figures are the manufacturer’s stated maximums. The test results page shows what was measured, by whom and under which conditions.

See the test results

Models and specifications

Two standard models cover water and wastewater applications. We recommend the model for your basin in the quotation.

Hexa-Cover® R90 Hexa-Cover® R114
Diagonal measure 18.0 cm 22.8 cm
Height 5.0 cm 6.0 cm
Tiles per m² 43 28
Weight per tile about 120 g 243 g
Weight per m² of cover 5.2 kg 6.8 kg
One big bag covers 50 m² 42 m²
Big bag weight 265 kg 285 kg
Big bag size 1.0 x 1.3 x 2.5 m 1.3 x 1.3 x 2.5 m
Material Recycled polypropylene, made without Freon or other harmful substances
Warranty and expected life 10 years warranty, 25 years expected lifetime
Independent tests DLG APPROVED (odour and ammonia) and AS/NZS 4020:2018 (drinking water contact), both tested on R114

Oil, gas, chemicals and hot liquids: separate Hexa-Cover® Oil and Gas, API, Heavy Duty and Extreme Duty versions are made for hydrocarbons, solvents and high temperature liquids. See Oil and Gas Duty, or tell us the liquid and temperature in the quote form.

Built as a solid tile

The way a floating element is built decides how long it lasts. Hexa-Cover® tiles are solid:

  • No hollow chambers that can crack and fill
  • No water ballast inside. Nothing can leak out of a tile into the liquid you are covering
  • No blow holes or injection holes, and no weak spots
  • No openings to clog with sand, debris or algae
  • Unaffected by rain

Why operators choose it

  • Installed without special equipment, in a full or an empty tank
  • Spreads out and adapts to level changes by itself
  • Fits every shape and geometry
  • Unlimited access to the liquid for pumps, sampling and service
  • Allows aeration, so aerobic conditions are maintained
  • No running, repair or maintenance cost, and no supervision needed
  • Does not change the look of the landscape the way a roof or tent does

Liquids and applications

Water

  • Raw water and drinking water
  • Irrigation water
  • Cooling and process water
  • Recovery water and boiler feed water
  • Fire water

Wastewater and waste

  • Sewage and municipal wastewater
  • Industrial wastewater
  • Landfill leachate
  • Spill-over and emergency tanks
  • Manure, slurry and biogas storage

Industry and mining

  • Tailings ponds
  • Leach solution ponds (ILS, PLS)
  • Chemicals
  • Hydrocarbon contaminated wastewater
  • Crude oil and refined products, with the Oil and Gas versions

Installation and operation

The main points from the manufacturer’s instructions for use, which are written for slurry tanks and lagoons.

  1. Check inlets and outlets. Openings must be smaller than the tile so tiles cannot enter pipes or pumps.
  2. Lift and pour. Each big bag is lifted over the edge with the opening facing down and emptied onto the liquid. Use at least two people and secure the person at the bag against falling in.
  3. Add about 90% first. Pour in the rest a couple of days later, to avoid overfilling.
  4. Empty tank? Tiles can be dropped onto a dry concrete floor from up to 5 m.
Instructions for use (PDF) Installation page

Day to day

  • Small gaps are normal. About 5% of the surface stays open, along the wall and between tiles. Do not fill the gaps with extra tiles; they let the cover keep its structure.
  • Wind. In strong wind, tiles on large surfaces can ride over each other. They return to their pattern when the wind drops.
  • Mixers and pumps. Keep mixing equipment 1 to 1.5 m away from the tiles and pump from below the surface.
  • Do not walk on it. The cover does not carry weight. Keep the same fencing and access rules as for open liquid.

Product questions

Multiply the liquid surface area in m² by 28 for R114 or by 43 for R90. A 1,000 m² pond needs about 28,000 R114 tiles, which is 24 big bags. The quote form calculates this for you.

R114 is the larger and heavier tile: 22.8 cm across and 6.8 kg per m² of cover, against 18.0 cm and 5.2 kg per m² for R90. The independent odour, ammonia and drinking water tests were carried out on R114. We recommend the model for your basin when we quote.

Not if the inlet and outlet openings are smaller than the tile, which is the first thing to check before installation. Pump or draw off from below the surface and keep mixers 1 to 1.5 m from the tiles.

No. It covers up to 99% of the surface, and in practice about 5% stays open along the walls and between tiles. It is not gas-tight and cannot be used to collect biogas.

Recycled polypropylene, moulded as a solid tile. No Freon or other harmful substances are used in production.

The warranty is 10 years and the expected lifetime is 25 years.

Tell us the size of your tank or pond

With the surface area, the liquid and the location we will recommend the model and prepare a quotation.