Adapting Construction Techniques for Harsh Weather: The Revolutionary D-Max Wall Assembly System

27 May 2024

Boisbriand, Qc

The construction landscape is rapidly evolving, particularly in the face of Canada's increasingly unpredictable and extreme weather conditions. These environmental challenges not only strain project timelines and budgets but also test the resilience and adaptability of builders and contractors. The tangible effects of Canada's harsh weather are evident in delayed projects, escalated costs, and a host of operational hurdles, underscoring the need for the construction industry to innovate and adapt.

The relentless downpours and the bitter cold of winter, now more frequent than ever, present significant obstacles. These conditions can hinder worker performance, compromise material integrity, and reduce the efficiency of construction machinery. For instance, concrete and mortar may not set correctly at stormy and low temperatures, while metallic components can become brittle and prone to failure. A 2021 study by the Canadian Construction Association highlights adverse weather as a leading cause of project delays, capable of pushing back timelines by weeks or months.[1]

Economic Impacts

The financial toll of constructing during inclement weather is significant, with cost overruns stemming from cold-weather projects estimated between 10 to 20 percent. These overruns account for additional expenses incurred from specialized materials, equipment rentals, heating solutions, and overtime labor.

Extreme weather, especially heavy rainfall, can disrupt foundational work, framing, roofing, and other exterior tasks, prolonging project timelines and inflating costs. The need for enhanced drainage, waterproofing, and the use of durable materials becomes more pronounced under such conditions.

Productivity can plummet by up to 50 percent in extreme weather, attributed to more frequent breaks, slower work rates, and additional time needed for tasks like snow clearance or the setup of heating elements. Consequently, the productivity window narrows, leading to potential prolonged construction periods or higher costs for artificial lighting and shift work.

Safety and Material Wastage

Extreme weather also heightens workplace injury risks, as evidenced by a rise in incidents during colder months, including slip-and-fall accidents, frostbite, and hypothermia. These risks, coupled with the increased likelihood of material failures, can lead to higher insurance premiums, adding another layer of cost to construction projects.

Material waste rates escalate during adverse weather, primarily due to suboptimal storage conditions and the impact on the curing process of concrete, adhesive effectiveness, and the durability of materials. This can result in structural issues and potentially increase the building's long-term maintenance costs.

Innovative Solutions and Adaptations

In response, the construction industry is collaborating more with manufacturers and engineering consultants to develop materials and assembly methods tailored for harsh weather applications. A standout innovation is the D-Max wall assembly system, which offers:

• Cost and Time Efficiency: Spray foam application used in the D-Max wall assembly is viable in temperatures as low as -20C, eliminating the need for scaffolding or hydraulic elevators and minimizing machinery requirements.
• Installation Flexibility: Insulation can be applied during wall construction, foregoing the need for exterior compartmentalization, and reducing labour and construction costs.
• Enhanced Thermal Resistance: The assembly acts as insulation, air barrier, and vapor barrier in one application, enabling a high-performance, airtight system with minimal wall thickness.
• Safety and Speed: The assembly's interior-focused application method reduces the need for external scaffolding, decreasing rental costs, logistical challenges, and accident risks.

Moreover, with advancements like Heatlok® Soya HP, a closed-cell spray foam solution, builders can achieve superior insulation, air barrier, vapor barrier, and rain screen functionalities in one. This product, specifically designed for Canadian climates, features an environmentally friendly hydrofluoroolefin (HFO) blowing agent, boasting zero-ozone depletion potential and a global warming potential of less than one.

Since its introduction, over a hundred projects have implemented this innovative wall assembly. Huntsman Building Solutions has augmented the design of the assembly by integrating extra data and options, thereby enhancing its thermal performance. A notable example is the Canopée project in Trois-Rivières, carried out for the UTILE organization in collaboration with Blouin Beauchamp Architectes and general contractor L'intendant. This student housing project incorporated one of the newly added features: a thermal break between the exterior Z-bar and the steel stud. This adjustment significantly improves the energy efficiency of the assembly, thereby enhancing its effective R-value. Additionally, this modification allows for a reduction in insulation thickness while ensuring compliance with the required building codes, thereby eliminating the need for the more complex performance path evaluations.

The D-Max wall assembly embodies a shift towards faster, safer, and more cost-effective construction methods, significantly mitigating the adverse impacts of harsh weather. This assembly system, by enabling a more resilient building envelope, showcases the industry's dedication to overcoming weather-related challenges through technological innovation and strategic planning.

 

[1] https://www.cca-acc.com/wp-content/uploads/2021/03/Strength-resilience-sustainability-Full-Report-Final.pdf