Understanding Thermal Breaks in Building and Construction

High thermal-performing architectural aluminum products help improve the energy efficiency of buildings while helping to lower the operational carbon of the building. In this article, we review thermal breaks, the research and development process of understanding thermal break technology and how Kawneer designs systems that optimize occupant comfort, energy savings, sustainability and condensation resistance. 

What is a Thermal Break? 

A thermal break is an insulating material that is strategically placed between highly conductive structural components within the building envelope, acting as a thermal barrier to interrupt the flow of thermal energy. 

Since aluminum has a high level of heat transfer via conduction, a thermal barrier must be integrated into the system to minimize heat transfer. Without additional thermal barriers, weather extremes can permeate under-designed fenestrations, lowering the comfort of occupants and raising operating costs of the building. Made from low conductive materials, our resilient thermal barriers are used within framing systems to separate the interior metal from the exterior metal and reduce heat loss. 

Research and Development 

Every three years, the International Code Council updates model building codes, including energy efficiency requirements, that are followed by most U.S. states. These increasingly stringent building energy codes challenge Kawneer to create innovative solutions that support thermal technology. We invest in our research and development processes to better understand how thermal breaks can improve the performance of our products.    

We are committed to introducing thermal breaks into our curtain wall, storefront, windows, entrances and window wall systems to make these systems higher performing, allowing architects and building designers to achieve their design goals while also lowering the total operational carbon of buildings.   

Through our research and development departments, we are regularly assessing the newest materials available for thermal breaks. We are also looking at glazing—from warm edge spacers or triple glazing—to ensure our products are compatible with the glass and spacers of the future to meet those higher performance needs. 

Kawneer’s Thermal Break Technology 

We have a wide range of thermal barriers and products that cater to different load conditions of projects and consider the impact of tension, torsion and sheer. All three load conditions are transferred through the thermal barrier; therefore, a barrier must withstand these forces.  

Learn more about the various thermal break technology Kawneer offers: 

• IsoPour® Thermal Break Technology 

• • The patented IsoPour® Thermal Break technology merges industry-proven pour and debridge, and polymer isolator technologies, creating thermally broken assemblies for enhanced building energy efficiencies with high structural performance. This technology helps eliminate cold spots, reduce condensation and provides dual finish options for design flexibility. The unique thermal break allows for more complex aluminum extrusion shapes and a wider choice of locking option hardware for thermally broken doors. 

• Continuous Polyamide Thermal Break 

• • A continuous polyamide thermal break applied vertically and horizontally helps provide ultra-thermal performance levels. Extruded polymer inserts allow a great deal of flexibility – changing the depth of the infill from a double insulating glass unit (IGU) to a triple IGU is as easy as changing the depth of the thermal separator. Depending on the depth of the separator and IGU type, the performance can be thermal, high-thermal or ultra-thermal. This technology offers design flexibility for different exterior and interior finishes and allows architects and designers to take their vision to a new level, regardless of climate or location. 

• IsoLock® Pour and Debridge Thermal Break 

• • Pour and debridge (P&D) thermal breaks offer a cost-effective solution with superior thermal performance and a single-piece extrusion. Options are available in single and dual pocket designs. Factory-supplied P&D products involve pouring liquid urethane into a cavity or thermal pocket, allowing it to harden and cutting away a small section of aluminum opposite the pour area to fully separate the exterior aluminum from the interior aluminum. This thermal barrier enables professionals to reduce labor and costs as there are fewer parts to cut and assemble. 

• IsoStrut® Thermal Break 

• • The patented IsoStrut® Thermal Break method achieves a high-strength bond between the aluminum and the thermal break material, which creates a composite assembly suitable for use in monumental curtain wall systems. With the assembly comprising of two separate aluminum extrusions, different exterior and interior finishes are possible at very competitive prices. 

• IsoWeb® Thermal Break 

• • Consisting of two parallel glass-reinforced nylon strips installed continuously along the length of the extrusion, the IsoWeb® thermal break system improves the U-factor and CRF. The depth of the thermal break can accommodate standard insulating infills of 1” thick or it can be increased to accept high-performance, triple-sealed insulating units.  

• • Like the IsoStrut thermal break, two separate extrusions are used in the assembly, allowing for different finishes on the interior and exterior. The mechanical lock at the nylon/aluminum interface provides a stiff composite section which is used in windows and framing systems. 

Innovative Solutions for Increased Thermal Performance 

Drawing on a long history of innovation, Kawneer’s next-generation thermal break technologies inspire architects, contractors and glaziers to build toward a better future. Our high thermal-performing products are precisely engineered to help solve thermal challenges, supported by strict quality control throughout the manufacturing process.  

Download our Thermal Technology Brochure.

Discover our High Thermal Performance Technology.