Hexprotect® MAX R Insulated Floating Cover — R-17+ Closed-Cell Foam for Biogas Digesters & Heated Lagoons
Hexprotect® MAX R is an insulated hexagonal floating cover with an R-value of 17 or greater, engineered for thermal retention in anaerobic digesters, biogas lagoons, and cold-climate process water systems. Its 2.5–3" closed-cell polyurethane foam core reduces heating costs by up to 90% while maintaining 99% surface coverage for evaporation control and algae suppression.
R-17+
Insulation Value
90%
Heating Savings
99%
Surface Coverage
25+
Year Lifespan
The Problem: Heating an Open Lagoon Is Prohibitively Expensive
Anaerobic digestion requires sustained liquid temperatures — 35°C for mesophilic systems, 55°C for thermophilic — to maintain the methanogen populations responsible for biogas production. In an open or lightly covered lagoon, thermal losses to the atmosphere dominate the operating cost budget.
A single-acre open digestion lagoon in a temperate climate can require $80,000–$250,000 or more per year in heating energy to maintain process temperature — a cost that escalates dramatically in cold climates, high-altitude sites, or winter operating conditions. Without adequate insulation, biogas yield drops, methane production decreases, and operating economics collapse.
The Solution: R-17+ Foam Insulation Directly on the Liquid Surface
Hexprotect® MAX R eliminates the air-to-liquid interface that drives heat loss. Each tile encapsulates 2.5–3 inches of factory-bonded closed-cell polyurethane foam in a watertight HDPE shell. The foam's R-17+ insulation value forms a continuous thermal barrier directly on the digestion lagoon surface.
The result is up to 90% reduction in heating energy consumption — transforming a $200,000/year operating cost into $30,000. The typical payback period is 12–36 months. Over the 25+ year product lifespan, Hexprotect® MAX R delivers 10–20× return on the initial cover investment.
Hexprotect® MAX R Technical Specifications
Full engineering data and ROI framework for biogas and heated lagoon applications.
Product Specifications
| Surface Coverage | 99% |
| Insulation Type | Closed-cell polyurethane (PU) foam — continuous bonded layer |
| Foam Thickness | 2.5–3 inches (63–76 mm) |
| R-Value | R-17+ (highest insulation in AWTT range) |
| Insulation Rating | R-17+ (Maximum — top of AWTT range) |
| Heating Cost Reduction | Up to 90% |
| Buoyancy | 16 lb/ft² (78 kg/m²) |
| Wind Resistance | 40 MPH (65 km/h) |
| Evaporation Reduction | Up to 98% |
| Operating Temperature | −70°F to +160°F (−57°C to +71°C) |
| HDPE Shell Material | UV-stabilized HDPE — watertight, chemical resistant |
| Foam Bond | Factory-bonded closed-cell foam — no field assembly |
| Life Expectancy | 25+ years |
| Warranty | 10 years (manufacturer) |
| Maintenance | None required |
| Cost Indicator | $$$$ (premium — ROI-positive for heated applications) |
ROI Framework — Typical Heated Lagoon
| Typical Digester Heating Costs (Before Cover) | $80,000–$250,000/year |
| Heating Cost Reduction with MAX R | Up to 90% |
| Estimated Annual Savings (per acre) | $60,000–$200,000+ |
| Typical Payback Period | 12–36 months (varies by application) |
| Cover Lifespan | 25+ years |
| Net Lifetime Value (25-year period) | 10–20× initial investment |
Estimates based on typical North American installations. Contact AWTT for site-specific ROI analysis.
Why Hexprotect® MAX R Is the Standard for Biogas Insulation
The highest thermal insulation performance in the floating cover industry, combined with 99% surface coverage and 25+ year HDPE durability.
R-17+ — Maximum Thermal Insulation
2.5–3 inches of factory-bonded closed-cell polyurethane foam delivers R-17+ insulation — the highest thermal resistance of any product in the AWTT range. Maintains process temperature with dramatically reduced energy input.
Up to 90% Heating Cost Reduction
In anaerobic digestion and biogas production, maintaining mesophilic (35°C) or thermophilic (55°C) temperatures is the dominant operating cost. Hexprotect® MAX R reduces this heating demand by up to 90%, delivering ROI within 12–36 months.
Improves Biogas Yield & Treatment Performance
Stable digestion temperature is critical to methane-producing archaea activity. By eliminating temperature fluctuations, MAX R maximizes microbial population stability and biogas production rates.
99% Coverage for Maximum Evaporation & Algae Control
The hexagonal tile geometry achieves 99% surface coverage regardless of pond size or geometry — delivering full evaporation control, algae suppression, and odor management in addition to thermal insulation.
Factory-Bonded Closed-Cell Foam — No Water Absorption
Closed-cell polyurethane foam does not absorb water, maintaining its R-17+ insulation value throughout the product's 25+ year lifespan. The watertight HDPE shell protects the foam from process liquid contact.
Self-Interlocking — Full Pond Coverage in Hours
MAX R tiles self-interlock on the liquid surface like all Hexprotect® systems — no assembly, no tools, no heavy equipment. The complete cover system can be deployed on a new or existing pond in hours, not days.
Hexprotect® MAX R Applications
Specified wherever a heated liquid surface demands maximum thermal insulation to maintain process efficiency and reduce operating costs.
Biogas & Anaerobic Digestion
Mesophilic (35°C) and thermophilic (55°C) lagoon insulation for maximum methane yield and minimum heating cost.
Dairy & CAFO Manure Digesters
Farm-scale and large dairy anaerobic digesters — 12–36 month payback on heating energy savings.
Industrial Heated Process Ponds
Any industrial process lagoon requiring sustained elevated temperatures — chemical, food processing, pharmaceutical.
Wastewater Treatment Digesters
Municipal and industrial wastewater treatment anaerobic digesters — improves VS reduction and biogas production.
Mine Process Water (Cold Climate)
Cold-climate mine water treatment ponds requiring winter temperature maintenance for biological treatment.
Thermal Aquaculture Ponds
Aquaculture operations requiring controlled water temperature for fish or shellfish growth optimization.
Hexprotect® MAX R is one of only three AWTT covers to have survived real-world hurricane conditions — alongside Hexprotect® AQUA and Rhombo Hexoshield®. All AWTT covers at hurricane-impacted sites endured Hurricane Florence (2018), Dorian (2019), Nicole (2022), and Helene (Cat 4, 2024) with zero damage and zero repairs.
Related Engineering Guides
Verification & documentation
AWTT keeps lab reports and project certificates request-gated, while making technical documentation for Hexprotect MAX R available to qualified specifiers.
Request-gated
Certificates, SDS, and test reports
Request material certificates, SDS sheets, wind/UV/R-value reports, and third-party documentation for submittal packages.
Public data
Technical data and comparisons
Review HTML tables, JSON/CSV data, and public specifications for coverage, wind, buoyancy, R-value, and design life.
Frequently Asked Questions
Direct answers for engineering, procurement, and compliance teams evaluating AWTT floating covers.
What R-value does Hexprotect MAX R provide?
When should I choose Hexprotect MAX R?
Does Hexprotect MAX R still reduce evaporation and algae?
Do AWTT floating covers leach PFAS, BPA, BPS, or BPF into drinking water?
Can AWTT provide lab reports, SDS sheets, and material certifications for submittals?
Engineering Tools & Resources
Evaporation & ROI Calculators
Calculate evaporation losses, estimate surface area, and compare cost savings across cover systems.
Not Sure Which Cover?
Answer a few questions about your site conditions and get a personalized product recommendation.
Technical Specifications
View full engineering specs, wind resistance data, R-values, and material compliance details.
Calculate Your Heating Savings with Hexprotect® MAX R
Share your digester or heated lagoon dimensions, current heating costs, and operating temperature. AWTT's engineering team will provide a site-specific ROI analysis, specification package, and cover pricing — typically within 24 hours.