D-MAX WALL, THE ASSEMBLY THAT'S CURRENTLY REVOLUTIONIZING CONSTRUCTION METHODS
20 Jun 2025
Boisbriand, QC
In the ever-evolving construction industry, building methods are increasingly being shaped by the need for greater efficiency, sustainability, and cost-effectiveness. One innovation that is currently revolutionizing the industry is the D-Max Wall assembly developed by Huntsman Building Solutions. This groundbreaking approach is transforming how buildings are insulated, with significant advantages in energy efficiency, time savings, and labor costs. With D-Max Wall, builders can meet new energy requirements, reduce construction costs, and accelerate job site productivity.
What Is the D-Max Wall Assembly?
The D-Max Wall assembly is an advanced wall system that utilizes an innovative spray foam insulation technique to deliver high-performance thermal resistance, airtightness, and moisture control—all in one. This method allows for the installation of spray foam insulation from the interior of the building, making it highly adaptable and suitable for various weather conditions. It’s particularly beneficial for large-scale projects, as it eliminates many of the challenges traditionally faced during construction. The core feature of the D-Max Wall assembly is the integration of Heatlok Soya HP spray foam, a product that serves as an insulation, air barrier, and vapor barrier in a single application. This innovative material provides the three essential properties required for a building envelope while simplifying the construction process. The result is a faster, safer, of higher quality and more cost-effective installation that improves energy efficiency and accelerates project timelines.
Key Benefits of the D-Max Wall Assembly
- Weather-Resilient Spray Foam Application
One of the primary advantages of the D-Max Wall assembly is the ability to apply the spray foam insulation regardless of external weather conditions. The application can be done in temperatures as low as -20°C, allowing work to continue smoothly even in harsh winter conditions. Since the insulation is applied from the interior, there are no weather-related delays, which significantly speeds up the construction process. - Simplified Construction Process
The D-Max Wall assembly eliminates the need for scaffolding or hydraulic elevators, reducing the rental costs, logistics, and potential safety risks associated with these traditional tools. It also removes the need for exterior compartmentalization, which is typically required by building codes. This simplification results in fewer workers on-site, which reduces both labour costs and potential for accidents. Additionally, because the product serves as an all-in-one solution (insulation, air barrier, and vapor barrier), the construction process is streamlined and requires fewer materials and labor. - Time and Cost Savings
The ability to perform insulation as the walls are being built eliminates a significant amount of waiting time between stages of construction. Traditional insulation processes often require scaffolding or other tools that make the job more time-consuming and expensive. The D-Max Wall assembly, on the other hand, is much faster to install, which leads to quicker project timelines and cost savings. The exterior insulation being installed from the interior allows for the cladding to be installed much quicker. Furthermore, the reduced need for machinery and additional materials contributes to lower overall project expenses. - Energy Efficiency and Sustainability
Energy efficiency is one of the most important issues in modern construction. The D-Max wall assembly plays a crucial role in meeting this challenge by providing high thermal resistance and airtightness. It enables compliance with the new NECB 2015 energy efficiency standards with fewer products and a thinner wall than traditional assemblies.
This system helps buildings retain heat in winter and cool air in summer, resulting in significant savings on heating and air conditioning costs. The use of Heatlok Soya HP spray foam, certified as environmentally friendly and low in volatile organic compounds (VOCs), ensures better indoor air quality and reduces the building's overall carbon footprint.
How the D-Max Wall Assembly Works
The D-Max Wall assembly involves a unique application process that starts with the installation of regular steel studs. However, instead of installing the exterior sheeting directly on these studs, a Z-girt is placed horizontally on the studs. This Z-girt creates a gap between the studs and the exterior sheeting, which allows for the injection of spray foam insulation between the two.
The spray foam insulation, Heatlok Soya HP, is applied from the interior of the building. The foam fills the gap between the exterior sheeting and the studs, effectively cutting the thermal bridge that typically occurs at the studs. This application method provides the benefits of exterior insulation without the need for external application, which is particularly useful during harsh weather conditions.
This method replaces several traditional building materials, including exterior insulation (such as rock wool), the full-surface membrane, fiberglass cavity insulation, and the poly vapor barrier. By integrating all these functions into one product, the D-Max Wall assembly simplifies the construction process and reduces material costs.
The Environmental Impact and Sustainability of D-Max Wall
Sustainability is at the forefront of the D-Max Wall system. As building construction accounts for nearly 40% of global greenhouse gas emissions, reducing the environmental impact of construction materials is critical. Huntsman Building Solutions has made significant strides in creating environmentally friendly insulation products. Heatlok Soya HP spray foam, used in the D-Max Wall system, is certified with an Environmental Product Declaration (EPD), which provides transparency on the environmental impact of the product throughout its lifecycle.
Heatlok Soya HP also utilizes a fourth-generation hydrofluoroolefin (HFO) blowing agent, which has an incredibly low global warming potential (GWP). This makes it one of the most sustainable insulation options on the market. By reducing embodied carbon emissions and increasing energy efficiency, the D-Max Wall assembly contributes to the global effort to mitigate climate change.
Certifications and Testing
The D-Max Wall assembly has undergone rigorous testing to meet the highest building standards. It has successfully completed the CAN/ULC S101 test, a critical fire resistance standard, and is UL listed with the UL EW25 assembly. It also complies with CAN/ULC S134 for fire resistance, CAN/ULC S742 for air barrier systems, and ASTM E331 for water penetration, ensuring its reliability and performance in various conditions.
The product is Greenguard Gold certified, meaning it meets strict criteria for low VOC emissions. This certification supports better indoor air quality and makes the product ideal for green building projects, including those targeting LEED standards.
Conclusion
The D-Max Wall assembly by Huntsman Building Solutions represents a major leap forward in construction innovation. By combining thermal resistance, air barrier, and vapor barrier functions into a single spray foam application, it simplifies the construction process, reduces costs, and improves building performance. Its ability to be applied in challenging weather conditions, its sustainability credentials, and its ability to meet stringent energy efficiency requirements make it a game-changer for the industry.
As the construction industry continues to evolve, the D-Max Wall assembly stands out as an example of how innovation can drive efficiency, sustainability, and cost-effectiveness. Whether building in extreme cold or seeking to meet the growing demand for energy-efficient buildings, the D-Max Wall is poised to play a pivotal role in shaping the future of construction.