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I’m designing a high-performance commercial building with a unitized aluminum curtain wall, but we’re struggling with thermal bridging at mullions and anchor points. We need to maintain structural rigidity while improving insulation performance to meet passive design standards. Has anyone successfully integrated thermal breaks without compromising strength? Structural engineers, façade specialists, and building scientists—any tested solutions?
(Architect): Would pre-glazed, factory-assembled units improve quality control, or would that limit flexibility during installation?
(Energy Modeler - Passive Design): A full thermal analysis (THERM or WUFI) can show exactly where heat loss happens. Some projects overuse insulation in the wrong places while missing key bridging points.
(Building Performance Engineer): Agreed! A hybrid approach—combining thermal breaks, optimized anchor placement, and insulated spandrel panels—often works best.
(Structural Engineer - High-Rise Buildings): Reducing thermal bridging at anchors is tricky. Have you looked into stainless steel brackets instead of aluminum? Stainless steel has lower thermal conductivity and better strength retention.
I haven’t considered that—would stainless steel increase installation complexity or add too much weight?
(Building Scientist - Thermal Performance): If thermal breaks alone aren’t enough, consider adding aerogel-filled spacers at high-conductivity joints. They provide excellent R-values without adding bulk.
(Façade Consultant): Good point! We’ve also seen vacuum-insulated glazing spacers work in cold climates.
(Façade Engineer - Curtain Wall Systems): We’ve used polyamide thermal breaks inside aluminum mullions to reduce conductivity, but you need to verify the shear strength and expansion properties match your system.
Thanks! How do you prevent air and moisture infiltration at thermal break connections?
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(Contractor - Façade Installation): Whatever solution you pick, make sure the assembly tolerances allow for on-site variability. Some thermal break inserts don’t handle field conditions well, leading to sealant failures and air leaks.