Aama Tir-A8-04

A M E R I C A N A R C H I T E C T U R A L
AAMA TIR-A8-04
Structural Performance
of Composite Thermal
Barrier Framing Systems
M A N U F A C T U R E R S A S S O C I A T I O N
TABLE OF CONTENTS
1.0 Foreword...........................................................................1
2.0 Introduction ......................................................................1
3.0 Thermal Barrier Materials.....................................................3
4.0 Design Guidelines...............................................................4
5.0 Environmental Impact .......................................................20
6.0 Testing............................................................................21
7.0 Appendices ......................................................................29
8.0 Attachments ....................................................................56
9.0 References.......................................................................62
AAMA. The Source of Performance Standards, Product Certification and

Educational Programs for the Fenestration Industry.
This voluntary specification was developed by representative members of AAMA

as advisory information and published as a public service. AAMA disclaims all
liability for the use, application or adaptation of materials published herein.
© 2004
American Architectural Manufacturers Association
1827 Walden Office Square, Suite 550, Schaumburg, IL 60173
PHONE 847/303-5664 FAX 847/303-5774
EMAIL [email protected] WEBSITE www.aamanet.org
All AAMA documents may be ordered at our web site in the “Publications Store”.
Revised Date: 10/2004 Released Date: 12/2004

1.0 FOREWORD
The worldwide manufacturers of fenestration
products have several materials from which to
produce their component products. Aluminum is
one of the preferred materials of choice. However,
because of aluminum’s high thermal conductivity,
improved thermal performance for this material is
of prime importance. Many thermal barrier
designs, which accomplish this end, have been
used or are in use currently. The method used in
all cases is to interrupt the continuity of the
framing system with the inclusion of a low
conductance material. This is commonly referred
to as a thermal barrier. With a properly designed
thermal barrier product, the transfer of the thermal FIGURE 1 – TYPICAL POURED AND DEBRIDGED
energy through an architectural framing system is THERMAL BARRIER ALUMINUM EXTRUSION
reduced. This interruption of energy flow has
obvious benefits in substantially reducing the total
energy consumption of the building of which the 2.1.1 Definition of Poured and Debridged Design
end product is a part. The thermal barrier will also An aluminum composite framing member, consisting of single
effectively improve the resistance of the framing extruded aluminum sections separated by a thermoset material
members to condensation or frost formation. providing a structural thermal barrier. The thermoset material is
These thermal barrier systems allow aluminum to poured into the cavity of the extrusion. After curing, the extruded
provide thermal performance comparable with bridge is removed. The resultant framing member is a composite
other framing materials. member consisting of interior and exterior aluminum sections
separated by a structural, insulating thermal barrier. (See Figures 1
Though there are several thermal barrier systems and 2).
in use today, the scope of this document will
address the composite thermal barrier systems that
are the most widely used, as known by this
document’s authors. Guidelines for these framing
systems are offered on cavity design, thermal
barrier material, selection, testing manufacturing,
fabrication, installation and environmental
performance. The intent of this report is to provide
the design professional with sufficient information
to intelligently evaluate composite thermal barrier
systems.
2.0 INTRODUCTION
2.1 Definition of Framing with a Structural
Thermal Barrier
An aluminum composite framing member
consisting of an interior and exterior extruded
aluminum section. The two sections are joined FIGURE 2 – TYPICAL POURED AND DEBRIDGED
by a structural thermal barrier material to THERMAL BARRIER COMPOSITE SECTION
improve the thermal performance of the
composite section.
AAMA TIR-A8-04 Page 1

2.1.2 Definition of Mechanically Locked Design However aluminum is one of the most thermally
An aluminum composite framing member, consisting of individual conductive metals. This high thermal
interior and exterior extruded aluminum sections separated by a conductance has been a cause of concern related
preformed thermal barrier. First, both the interior and exterior to the use of aluminum in fenestration products,
aluminum extrusions are knurled. The structural thermal barrier principally energy loss and associated
material is then inserted into the knurled extruded cavity of both condensation. In response to these concerns,
the interior and exterior portions and after rolling (crimping) the designers have devised methods to separate the
mechanical locking process is complete. (See Figures 3 and 4). exterior metal surfaces from the interior metal
surfaces, thus greatly reducing the heat and cold
transfer. These techniques generally incorporated
some type of insulating medium with structural
properties.
2.2.1 History of Poured and Debridged

Thermal Barriers
In 1962, the Soule Steel Company of San
Francisco announced a "new method of insulating
aluminum windows and curtain-wall systems,
which eliminates internal frost build-up in cold
climates and is up to 50 percent cheaper than
former, less efficient techniques." Soule called
this system Artic Wall. This development was an
important milestone, because the Soule technique
FIGURE 3 – TYPICAL MECHANICALLY CRIMPED IN resulted in the first window product to be
PLACE THERMAL BARRIER EXTRUSIONS produced economically with excellent control of
dimensional tolerance. The first notable
application of this technology which later became
known as poured and debridged was for windows
and curtain-walls in the construction of the State
Office Building in Fairbanks, Alaska, in 1962.
2.2.2 History of Mechanically Locking Thermal

Barriers
The mechanical locking thermal barrier system
originated in Europe in the early 1970’s.
Ensinger GmbH and Wicona, in order to meet
the needs of a specific project, developed the
structural thermal barrier system. The first
known installation of a mechanical locking
thermal barrier was in 1978. The first usage in
the United States came a little over ten years
later, in the spring of 1991. The thermal barrier
was used in the Jackson County Public Hospital.
It was the first use of a mechanical locking
thermal barrier that had been produced in the
FIGURE 4 – TYPICAL MECHANICALLY CRIMPED IN
United States. These windows went into service
PLACE THERMAL BARRIER COMPOSITE SECTION
in the spring of 1991 and are still in service as of
the date of this printing.
2.2 History
Throughout the world, aluminum extrusions have become the
Along with the advancements in insulating glass,
preferred construction material for windows and doors. The reasons
improved sealants, weather stripping and high
for the popularity of aluminum are many. Aluminum extrusions are
performance finishes, thermal barriers have
lightweight with one of the highest strength to weight ratios of any
provided a great impetus for the growth of
material. For the designer, they offer an unlimited variety of shapes.
aluminum as the preferred material for
They are produced at close dimensional tolerances, providing for
architectural framing. Since the early seventies,
excellent operational fit and structural stability. Aluminum is not
thermal barriers have achieved such universal
subject to warping, rust or vermin damage. Aluminum accepts many
acceptance that they are now considered a
finishes allowing for a wide variety of color applications.
standard way to produce energy efficient
Aluminum is the most recycled material used for framing.
fenestration framing products.

To ensure continued reliability and technical improvements
of thermal barriers, AAMA organized the Thermal Barrier
3.0 THERMAL BARRIER MATERIALS
Structural Task Group at its October 1981 Annual Meeting.
This committee was comprised of experts in the field, Any material that improves the thermal performance of an
including design engineers, process engineers, corporate aluminum window frame without compromising the
and marketing managers and chemists. It was decided at structural integrity of the window may be used as a thermal
this meeting that the main responsibility of the task group barrier. All products used for thermal barrier applications
would be to prepare a Technical Information Report (TIR) must have a set of minimum performance properties.
for the manufacturers of windows, doors, curtain walls, Properties such as tensile strength, elongation, impact
storefronts, skylights and other glazed architectural resistance, thermal conductivity, flexural modulus,
products that would establish guidelines, performance adhesion properties and heat deflection temperatures
standards, processing recommendations and test methods should all be considered during the design and application
for thermal barriers. stage.
Given the significant innovations and changes in thermal After reviewing all of the technical data, a product that
barrier design, AAMA charged the Thermal Barrier Task meets the general product parameters should be selected
Group to update the current TIR-A8-90. The mission of and then run under typical plant conditions in extrusions
the Task Group was to revise and expand the TIR-A8-90 designed for the particular application. Samples of these
document to include innovations in products and testing. extrusions should then be tested to confirm that the product
This document is the result of that effort. will perform to the expected level.
2.3 Effect on Condensation Resistance Factor (Crf) Regardless of the type of thermal barrier product or
and Thermal Transmittance (U Factor) material chosen, care must be taken in its design and
The thermal barrier serves to isolate the aluminum on the application as the performance properties needed for each
exterior of the framing system from the aluminum on the application can vary significantly. The manufacturer should
interior. A properly designed system will still maintain the be consulted throughout all aspects of this process. This
structural integrity of the framing while not permitting a remains the key to the success of any product chosen.
thermal short circuit between exterior and interior metal.
It is important to note that an excellent material will not
A thermal barrier provides an effective method of limiting perform in a poorly designed thermal barrier cavity, nor
the formation of condensation and frost on the interior will a poor material perform in a properly designed cavity.
frame. Condensation at this point can damage interior trim Both the cavity design and the material must be correct. In
and wall covering or at the very least be a nuisance to the this specification we will discuss two thermal barrier
building owner. The ability of a framing system to resist materials, one being a poured urethane (a mix of two
condensation formation is expressed by the Condensation components, used in a poured-and-debridged system) and
Resistance Factor (CRF). AAMA document 1503, the other being a preformed, engineered profile extruded
“Voluntary Test Method for Thermal Transmittance and into a thermal barrier shape. There are other materials that
Condensation Resistance of Windows, Doors and Glazed may be used as composite thermal barrier materials but
Wall Systems” provides guidance to the design they will not be discussed here in detail; however the
professional on determining the proper Condensation analytical procedures in this document would still be
Resistance Factor requirements for a project. In general, applicable.
framing systems with thermal barriers have significantly
better condensation resistance than those without. The final thermally separated composite extrusion must
exhibit the following properties:
Like CRF, the coefficient of thermal transmittance (U
1. Resistance to deflection must be adequate to meet the
Factor) for the glazed framing system will also improve
requirements of the intended application at the anticipated
when thermally broken sections are utilized. The thermal
loads and ambient conditions.
barrier effectively reduces the amount of heat transfer from
one side of the extrusion to the other. The effect of thermal 2. Resistance to torsion must be greater than the expected
sections on the U Factor of the composite glazed product forces caused by the loads on the frame.
will depend upon the ratio of the metal area to the glass
area. 3. Resistance to shear must be greater than the expected
forces caused by the differences in inside and outside
temperatures, weight of the glazing material and structural
composite action of the assembly.
4. Resistance to wind loading must be adequate to

withstand the continuous pumping action caused by
variations in wind loadings.

5. It must be able to support static loads caused by 4.1.1 Poured in Place Cavity Design
the weight of the glazing material or hardware Only single profile thermal barrier cavities of general shape shown
hung on the window. in Figures 5 to 9 are addressed. Design criteria range from thermal
to structural to extrudability which are often at odds with each
6. It must be designed so as to minimize dry other, and are summarized as follows:
shrinkage. (If applicable)
1. Maintain an appropriate width-to-depth ratio on cavity dimensions
7. Resistance to distortion and impact loading as shown in Figure 8. This helps promote good flow into the cavity
must be adequate to the end use of the product. during pouring and develops optimum structural strength in tension
and torsion for any given amount of thermal barrier material.
4.0 DESIGN GUIDELINES Unusual profiles may involve significant deviations in structural
integrity. In addition the design must stay within extrudability limits
4.1 Material Selection of the aluminum by employing gap width ratios (cavity area divided
The information contained in this section is by the square of the gap width) less than 3.5.
garnered from the shared experiences of AAMA
members involved in supplying and/or THERMAL FILLING
manufacturing of thermal barrier products. They BARRIER NOZZLE
are not intended to be prescriptive or all inclusive. MATERIAL
Commonly accepted engineering practices should
be followed in the design of any component of a
framing system.
Following are cavity design guidelines for TENSILE AREA

structural thermal barrier sections. These DEPTH
guidelines are based on time-tested design
parameters and are not intended to stifle design
innovation or creativity, but merely to present
those features, which have worked well in the
past. WIDTH
POURED CAVITY
FIGURE 5
2. Design the temporary aluminum bridge for removal without

removing thermal barrier material in the throat area "F" as shown
in Figure 9 or creating indentations for standing water as shown in
Figures 6 and 7.

FILL FILL
FILL DEPTH
A B
BRIDGE
TYPE #1 INDENTATIONS (2) BRIDGE REMOVED FOR FULL
DEPTH OF BRIDGE THICKNESS
ONLY AND FOR FULL WIDTH
SEPARATION DIMENSION OF SEPARATION DIMENSION
FILL FILL
C D
IRREGULAR CUT - USUALLY

CUTTING TOO DEEP
FROM MULTIPLE SAW BLADES
(BEYOND BRIDGE THICKNESS)
WEAKENS THERMAL BARRIER
WEAKENS THERMAL BARRIER
AND CREATES STRESS POINTS
FILL
TYPE #1
E BRIDGE
DETAILS
BRIDGE NOT REMOVED
FULL WIDTH OF
SEPARATION DIMENSION
FIGURE 6

FILL FILL
A B
BRIDGE
TYPE #2
(RAISED)
DEBRIDGING WILL LEAVE
SEPARATION DIMENSION A LINE OF BARE ALUMINUM
EACH SIDE OF CAVITY
SMOOTH FLUSH SURFACE
FULL CAVITY DEPTH LEFT
AFTER BRIDGE REMOVAL
FILL FILL
C D
CUTTING TOO DEEP BRIDGE NOT REMOVED

(BEYOND BRIDGE THICKNESS) FULL WIDTH OF
WEAKENS THERMAL BARRIER SEPARATION DIMENSION
FILL
TYPE #2
E BRIDGE
DETAILS
BRIDGE NOT FULLY
REMOVED MAY CAUSE
STRESS IF CLEARANCE
IS INSUFFICIENT
FIGURE 7

In removing the bridge avoid irregular cuts or cutting too deep as 6. Ensure that the cross-sectional profile and
shown in Figures 6C, D and 7C as this will weaken the structural location of the thermal barrier cavity does not
integrity of the thermal barrier. Failure to fully remove the bridge as create thermal "short circuits" at joinery whenever
shown in Figure 6E may affect the thermal transmittance of the practical. In doing this, the basic design of the
section and may cause clearance problems as shown in Figures 7D system must be reviewed, i.e., square cut vs.
and 7E. mitered construction, etc.
3. All interior corners of the cavity should be radiused 0.8 mm (1/32 7. In situations where sections are dependent on
in) minimum as shown in Figure 8. adhesion for shear strength, maximize the surface
area within the cavity.
These radii help eliminate voids and pin holes in the fluid during the
viscous flow pouring process. Greater surface area will result in lower shear
stresses being developed at the bond line during
flexure. Surface treatment is addressed in Section
POUR SIDE 4.2.
EXTRUSION GAP
8. Prevent disengagement of the thermal barrier
material under tensile and torsional loads by
providing a positive mechanical interlock in the
cavity profile.
9. Position the thermal cavity where it will

perform most effectively thermally. This requires
the careful study of the temperatures and
longitudinal shear forces in flexure, which will
occur at different locations within the system.
Such analysis would usually result in a cavity
located at or near the glazing pocket. In many
RADIUSED instances, a thermal barrier location yielding
CORNERS optimal condensation resistance will not yield the
RETENTION
LUGS FOR MECHANICAL INTERLOCK lowest possible frame U Factor. Thermal barrier
WITH THERMAL BARRIER MATERIAL location near the exterior minimizes the
possibility of hardware "short circuits" resulting in
better thermal performance.
EXTRUDED CAVITY
10. Position the thermal barrier to avoid direct
FIGURE 8 exposure to the elements. This assures thermal
integrity, avoids appearance problems and
4. Provide a "fluid head" to force the viscous fluid into all recesses minimizes the possibility of ultraviolet
of the cavity when pouring. degradation.
5. Keep the thermal barrier cavity profile symmetric whenever 11. Cavities smaller than those shown in Figure 9
practical. This avoids eccentric loading in tension and torsion. are outside of normal industry practice, therefore
use of such a cavity should be justified by a
complete set of physical and thermal tests of the
composite section to demonstrate that the section
meets or exceeds the minimum strength and
thermal performance requirements.

0.9 mm (0.031) MIN. RAD.
WALL THICKNESSES PER TYPICAL
JOB SPECIFICATIONS AND EXTRUSION GAP
STRUCTURAL REQUIREMENTS SEPARATION
(TYP.) "A"
LUG HEIGHT THROAT FILL

LOCAL AREA "B" "D" "F" DEPTH
HEIGHT
LOCK AREA
TYPE #1 BRIDGE "C" DEPTH
SHOWN
"E"
WIDTH
CAVITY DATA
A B C D E F AREA VOLUME
DESIGNATION
mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm2 (in2) ml/m (in3/ft)
AA 5.18 (0.204) 6.86 (0.270) 2.79 (0.110) 1.02 (0.040) 10.77 (0.424) 4.83 (0.190) 70.96 (0.110) 71 (1.320)
BB 6.35 (0.250) 7.14 (0.281) 4.06 (0.160) 1.14 (0.045) 14.48 (0.570) 4.85 (0.191) 100.65 (0.156) 101 (1.872)
CC 6.35 (0.250) 7.92 (0.312) 4.78 (0.188) 1.27 (0.050) 15.90 (0.626) 5.38 (0.212) 123.23 (0.191) 123 (2.292)
DD 7.92 (0.312) 8.89 (0.350) 5.49 (0.216) 1.57 (0.062) 18.90 (0.744) 5.74 (0.226) 165.81 (0.257) 166 (3.084)
EE 9.53 (0.375) 9.53 (0.375) 5.74 (0.226) 1.57 (0.062) 21.01 (0.827) 6.38 (0.251) 199.35 (0.309) 199 (3.708)
Suggested dimensions and proportions are representative of those which have provided successful performance in most applications.
FIGURE 9
12. Test all design variations for structural integrity.

Whenever testing new variations ensure that a
statistically valid sample size is tested.
The design guidelines given above are not meant to be

all inclusive. Commonly accepted engineering
practice should be followed in the design of any
component of a framing system. However, following
these design guidelines should avoid most problems,
when used in conjunction with guidelines for
application and material quality presented elsewhere in
this report.
FIGURE 10 – TYPICAL THERMAL BARRIER CAVITY
4.1.2 Mechanically Locked, Preformed Thermal
Barriers, Cavity Design The cavity allows for the structural thermal barrier to be
The cavity shown in Figure 10 is for a single thermal inserted into the aluminum extrusion. The design of the cavity
barrier strut. Normal use of mechanical locking is slightly oversized to allow for the knurling of the sidewalls
thermal barrier systems has the profiles being used in before the profile is inserted. The profile can be inserted into
pairs. This allows for one thermal strut to be in the aluminum either by hand or by an insertion machine.
compression and the other in tension to provide the
maximum strength for fenestration products. The knurled surface on both the hammer and anvil side of the
aluminum cavity create the mechanical lock between the
aluminum and the thermal barrier holding the window product
together.

KNURLING OF THE ALUMINUM CAVITY An aluminum extrusion without sufficient knurling will
Before the thermal barrier is inserted into the aluminum allow for the thermal barrier to be inserted very easily.
extrusion both the interior and exterior sides of the The knurling will not provide any resistance in sliding the
extrusion need to be knurled. The key to the strength of a thermal barrier profiles into the respective aluminum
mechanical locking, pre-formed thermal barrier system is cavities. However, without the proper knurling on the
a proper knurl on the aluminum extrusions. A proper aluminum cavity a high shear strength value for the
knurl will have sharp edges that allow the notches to be aluminum extrusion with a thermal barrier cannot be
rolled into the thermal barrier to make contact and hold it achieved.
in place. A knurling machine is used to place notches on
the aluminum extrusion. Figure 11 shows the difference However, an aluminum extrusion with the knurling too
between a proper and an incorrect knurl on the aluminum deep will not allow for the thermal barrier to be inserted
cavity. into its cavity. The teeth on the aluminum from the
knurling process will grab and hold onto the thermal
barrier preventing it from being slid into the aluminum
extrusion. But, more important than the depth of the
knurling is the shape of the teeth on the knurl, if the
knurling has sharp edges like in the proper example above
then a high shear strength can be achieved during the
INCORRECT PROPER crimping process on the aluminum extrusion.
FIGURE 11
ROLLING OF THE ALUMINUM-THERMAL
Besides having a knurling on both sides of the aluminum BARRIER COMPOSITE
cavity, the knurling needs to be of equal depth on both After the Thermal Barriers (2) have been inserted between
sides of the cavity. Unequal knurling on the two sides of the two halves of the aluminum extrusion, the assembly is
the aluminum cavity will produce inconsistent shear now ready for the rolling process. The mechanical lock is
strength values across the aluminum assembly. Also, created when the aluminum cavity passes between the
uneven knurling will create problems inserting the rolling discs and the “hammer” on the aluminum is forced
thermal barrier into its pocket. The knurling being too into the thermal barrier.
deep on the one side will grab the thermal barrier and not
allow for the thermal barrier to be inserted into the When rolling the aluminum composite, the window
aluminum cavity whether it be inserted by hand or manufacturer needs to be sure there is enough pressure on
machine. the rolling wheels to create the mechanical lock between
the thermal barrier and the aluminum extrusion. The
INSERTING THE THERMAL BARRIER INTO fabricator should consult the instruction manual on his
THE ALUMINUM CAVITY specific insertion equipment for setting up the machine to
The thermal barrier is inserted into the pocket in the ensure the rolling machine will crimp the aluminum with
aluminum cavity by sliding it in from one end of the enough force to create the necessary shear strength for
extrusion. This can be done by hand or by machine, one your fenestration products.
profile at a time or both at the same time. The degree of
difficulty in inserting the thermal barrier into its cavity Also, the rolling wheels need to be properly aligned on
depends on the depth of the knurling in the cavity. the aluminum extrusion to ensure the hammer is rolled
into the insulating strut. If the rolling wheels are not
positioned properly, the aluminum can be cracked during
the rolling process. Also, if the discs are not positioned
properly, the hammer on the aluminum cavity will not be
rolled into the insulating strut creating the shear strength
for the product.

FIGURE 12
After the rolling of the aluminum extrusion, the profile is due to a lower temperature at the channel wall created by
ready for use. Random testing of the assembly is the heat sink effect of the aluminum. The rate of cure, or
recommended to ensure the quality and consistency of the speed of solidification, is temperature dependent. The
insertion process. hotter the temperature is, the faster the cure. As a result,
the material near the channel remains more fluid than the
The design guidelines given above are not meant to be all- core material and permits wet shrinkage to occur.
inclusive. Commonly accepted engineering practice should Advances in urethane resin formulations have reduced the
be followed in the design of any component of a framing potential for wet shrinkage.
system. However, following these design guidelines
should avoid most problems, when used in conjunction When dry shrinkage occurs, it is a result of poor adhesion
with guidelines for application and material quality of the thermal barrier to the substrate with which it is in
presented elsewhere in this report. contact. Dry shrinkage is an end-to-end exposure of cavity
walls after curing and thermal cycling. Typically, the cut
4.1.3 Shrinkage end of the thermal barrier, which is initially flush with the
Some thermal barrier systems can experience two kinds of end of the extrusion cavity, pulls back or retracts evenly
shrinkage, wet and dry. Wet shrinkage is the end-to-end leaving a gap at the end. No thermal barrier material is
shrinkage of freshly poured material as it gels, sets up and apparent on the exposed cavity walls, hence the term ‘dry
cools within the extrusion. Dry shrinkage is the end-to-end shrinkage’. Since dry shrinkage occurs after the extrusion
contraction of the thermal barrier after the composite is cut and fabricated into window and door units, gaps
section has been cut to size. Dry shrinkage may occur after could open up at the corners causing water and air leakage.
the composite has experienced repeated thermal cycling.
Dry shrinkage will typically occur after repeated exposure
4.1.3.1 Poured and Debridged Shrinkage to environmental cycling. The large difference in
There are a number of factors that are known to contribute coefficients of thermal expansion, between the aluminum
to wet shrinkage. These factors are gel time, peak and the thermal barrier, is one factor that creates stresses
exotherm temperature reached by the resin in the cavity, that can initiate dry shrinkage. Aluminum has a coefficient
cavity size, extrusion mass, and the temperatures of the of thermal expansion of 2.3 x 10-5 mm/mm • °C (1.3 x 10-5
resin and the aluminum at the time of pouring. These in/in • °F) while typical thermal barrier resins are of 9.0 to
factors are also dependent on the specific resin 12.6 x 10-5 mm/mm • °C (5 to 7 x 10-5 in/in • °F) or four to
formulation used. Physically, what happens is the five times more than aluminum. As a result, the thermal
material in the center of the pour solidifies faster than the barrier attempts to change dimensions more than the
material near the walls of the aluminum cavity. This is aluminum with the same temperature changes. At elevated

temperatures the thermal barrier tries to expand more than 4.1.3.4 Mechanical Locking Distortion of Aluminum
the surrounding aluminum while at lower temperatures the During the crimping process the aluminum extrusion can
thermal barrier will try to contract more. A second factor, be distorted. However, the affects of the distortion are
which could affect dry shrinkage, is the temperature negligible if the insertion process is done properly. Most
difference between the exterior and interior aluminum crimping machines provide three specific steps within the
facing sections. There are ways to eliminate the potential crimping process.
for dry shrinkage. Surface preparation, mechanical
staking, chemical adhesion, and proper selection of finish Step 1 – Straightening of the aluminum composite with the
and surface treatments are the primary ways to avoid dry thermal barrier installed
shrinkage. Conditions that promote dry shrinkage are
cavity surfaces contaminated with grease, oil, dirt or die After the thermal barrier is inserted in the aluminum
lubricants, metal surface pretreatments and seal coats that extrusions the composite section is ready for the crimping
do not achieve adequate adhesion to the aluminum, or process. The first step in crimping is to align the composite
thermal barrier material that does not adhere to the finish. section to ensure it is in the right position to complete the
For a discussion of finishes see 4.2.1. Generally, dry crimping process.
shrinkage has always been attributed to the thermal
barrier. The critical role of proper seal coat and finish Step 2 – Crimping of the Aluminum Extrusions
selection and preparation cannot be ignored. Typically,
finishes have coefficients of thermal expansion closer to Once the profile is aligned properly, it is ready to pass
the thermal barrier than the aluminum. If there is poor through the main crimping stage. This is where the
adhesion of the finish to the metal, dry shrinkage will mechanical lock between the thermal barrier and the
occur as the bond fails at the finish-metal interface. Cavity aluminum extrusions is actually created. During this stage,
design also influences the potential for dry shrinkage. the hammer side of the aluminum extrusion is pushed into
Some designs are more resistant to shrinkage than others. the thermal barrier profiles creating the lock between the
When in doubt, the framing designer or manufacturer aluminum and the thermal barrier.
should consult the thermal barrier resin supplier about
shrinkage. Step 3 – Profile Correction Stage
The final stage of the crimping process is the correction

4.1.3.2 Mechanical Locking Shrinkage stage to ensure that the aluminum is not distorted during the
Mechanical Locking Thermal Barrier Systems do not crimping process. The final stage ensures that the
experience either wet or dry shrinkage. In terms of wet aluminum is straight in both the up and down direction and
shrinkage, the mechanical locking thermal barrier is the left right direction. This ensures that the fenestration
usually an extruded engineering plastic that does not have product will be able to be manufactured from the aluminum
a set up or gel time. The material is extruded to shape and lineal containing the thermal barrier.
then installed in the fenestration product.
Over crimping in stage 2 could also cause distortion to the
The dry shrinkage problem occurs over thermal cycling of aluminum cavity. The window manufacturer needs to be
the fenestration product. The material chosen for the sure that they are following the insertion equipment
mechanical locking thermal barrier will determine if there instructions on the crimping of the aluminum extrusions to
will be any dry shrinkage. In cases, where the mechanical ensure that they are not applying to much pressure during
locking thermal barriers are glass-reinforced polyamides, the crimping which could distort the aluminum cavity.
there will not be any dry shrinkage. Glass reinforced
polyamides have a coefficient of thermal expansion Finally, in a mechanically crimped thermal barrier system,
almost identical to aluminum. This results in expansion the aluminum cavity is always changed during the crimping
and contraction of the thermal barrier and the aluminum process. The initial design of the aluminum cavity should
at the same rate during thermal cycling. This results in no take this in account so that the aluminum cavity after
dry shrinkage in a mechanical locking thermal barrier crimping will allow for the fenestration product to be
system. manufactured into its finished dimensions.
4.1.3.3 Aluminum Cavity Distortion 4.2 Cavity Surface Treatment
Distortion can be the result of a number of contributing The cavity should be clean, dry and oil-free before
factors; installing the thermal barrier material.
1. Cavity size and shape
2. Metal thickness of the cavity walls 4.2.1 Poured in Place Materials
3. Extrusion design Most designs rely on adhesion between polyurethane and
4. Processing parameters aluminum to maximize bending stiffness, minimize dry
shrinkage and prevent water from penetrating the
polyurethane-aluminum interface causing leakage or
freeze-thaw damage.

Due to variations inherent in manufacturing processes any finishing operation is performed on the aluminum, the
and project requirements, the surface treatment present thermal barrier supplier should be consulted to ensure that the
on interior cavity surfaces can vary widely from one mechanical lock between aluminum and thermal barrier will not
manufacturer, project or section to another. It is be weakened.
important that all possible surface treatments be tested
for adequate adhesion to polyurethane, for example: Once the thermal barrier is inserted into the aluminum cavity,
the complete section is ready to go through the rolling process.
*Mill Finish As the aluminum and thermal barrier pass through the rolling
Conversion Coating machine the hammer on the aluminum cavity is forced into the
Primer thermal barrier. The knurling on the aluminum is crimped into
Paint "overspray" the thermal barrier creating the shear strength of the
Organic Paints fenestration product.
Acrylic
Polyester 4.3 Manufacturing Poured and Debridged Thermal
Enamel Barriers
Polyurethane When applying polyurethane thermal barrier products, it is
*Fluoropolymer important to follow all of the manufacturers’ recommendations.
Anodic Finishes For this document, the manufacturing has been sub-divided into
Clear three separate and distinct phases:
Integral Color 1. Processing.
Electrolytically deposited color 2. In-plant Handling and Fabrication.
Anodic Finish Sealing Processes 3. Transportation and Installation of the Finished Product
Boiling Water Seal
*Nickel Acetate Sealing Additives The following sections will summarize generally acceptable
Anti-smut Additives procedures currently in use.
*Mill finish, fluoropolymer paint finishes and nickel 4.3.1 Material Processing
acetate sealing additives within the cavity have been General processing parameters for polyurethane thermal barrier
shown to adversely affect adhesion under some systems are contained in the following sections. Applicators
conditions and hence should be carefully evaluated. should follow the AAMA QAG-1 document for processing and
record maintenance and all of the suppliers quality control
Some designs employ a mechanical interlock and/or guidelines.
chemical surface preparations to limit differential
longitudinal movement between polyurethane and
aluminum. In all cases where adhesion is required for
proper performance, it is strongly recommended that
the finishing process be done before filling and
debridging. On occasion poured and debridged
extrusions require refinishing. Finishing processes
may involve temperatures and/or chemicals which can
adversely affect system performance. The supplier of
the thermal barrier material should be consulted when
analyzing the adhesive properties of the thermal barrier
material with the various surface finishes listed above.
4.2.2 Mechanically Locked, Preformed Profiles

In a mechanically locking, preformed thermal barrier
system, the type of finish on the material does not
directly affect the mechanical lock. However, the
thickness of the finish on the aluminum can affect the
shear strength of the assembly. Knurling wheels must
not only penetrate the thickness of the finish but also
the aluminum extrusions.
After the thermal barrier is installed some finishes can FIGURE 13 – TAPED EXTRUSIONS BEFORE POURING
be applied to the aluminum without affecting the shear (When required)
strength of the system. Powder coating and anodizing
should not hurt the mechanical lock between the
thermal barrier and the aluminum. However, before

4.3.1.1 Color, Mixed
A general description of color, e.g., black, clear,
brown, blue, etc.
4.3.1.2 Mixing Ratio

By weight, or by volume, according to supplier's
recommendations.
4.3.1.3 Viscosity, Mixed

Determine viscosity according to ASTM D2849,
the mixed viscosity is determined on uncatalyzed
materials. Viscosity on auto-catalytic materials
may be impossible to determine.
4.3.1.4 Gel Life

Gel time in seconds is the time for mixed
materials to change from a liquid to a solid. .
4.3.1.5 Debridging Time

The minimum time for the mixed material to
develop sufficient hardness to facilitate debridging
should be determined according to ASTM D2240.
4.3.1.6 Cure Time

The time needed for the product to develop
maximum physical properties. This will vary from
material to material and should be according to
the supplier's recommendations.
4.3.2 Thermal Barrier Material Quality

Control
A quality control check should be made on the
chemical and equipment at each start-up, and
recorded. These procedures should be per the
AAMA QAG-1, and consist of checks contained
therein.
FIGURE 14
4.3.3 Pouring
General pouring procedures to be followed by the manufacturer:
1. Material should be level and filled to the top of the cavity.
2. Nozzle settings and pour speeds should be such that little or no air
will be entrapped in the liquid fill material.
3. Appearance of the liquid surface should be smooth and free of

bubbles.
4. Processing should be done in a manner such that the cavity is held

upright and level until solidification has occurred.

4.3.4 Cure Time and Debridging 4.3.5.1 Handling in the Plant
Debridging time is largely dependent upon the chemical This section is designed for the manufacturer who keeps
characteristics of the material as provided by the supplier. filling, debridging, and fabrication operations in-house.
Debridging time may range from 3 minutes to 24 hours for The filled extrusions should not be abused after debridging.
safe debridging after pouring. Proper debridging technique The appropriate debridging time will be supplied by the
is largely dependent upon the following factors: thermal barrier resin supplier. The extrusions should be
stacked in such a manner as to protect their dimensional
1. Poured extrusion temperature prior to debridging. stability during cure. The extrusions should be fabricated
only after recommended physical properties of the thermal
2. Aluminum mass vs. cavity size and location. barrier are reached.
3. Cure time is affected by curing conditions, such as metal 4.3.5.2 Handling During Storage
temperatures, plant conditions; and should be in accordance This section can be used by both extruders and fabricators.
with the supplier's recommendations. Though the reasons for storage may vary, it is important to
ensure quality parts are available when needed, thus the
4. The hardness of the thermal barrier material in the cavity following guidelines should be observed:
should not be less than a durometer reading of 60 Shore D
recommended by the supplier. It is important to maintain Care must be taken when extrusions are going to be stored
dimensional stability during and after debridging. Stability in inventory. Extrusions need to be protected from damage
is affected by the plastic flow characteristics of the fill to the finish and distortion. Extrusions should be stored in
material. Extrusion "kick back" at the saw is another very symmetrical, banded bundles. Care must be exercised to
real danger of debridging material that is too soft. ensure proper band tensioning and extrusions should be
interleaved with paper. It should also be noted that putting
NOTE: Hardness must be measured on a smooth cut excessive weight on these bundles can cause distortion and
surface. other damage.
4.3.5.3 Handling During Packing and Shipping

5. Centering of the debridging cut should be between the In addition to the concerns of the previous two sections,
retention lugs of the extrusion to provide maximum there are conditions specifically related to shipping: heat,
mechanical interlocking of the profile. cold, shock, and vibration are major considerations.
Because of these factors, it is important to keep the
6. Debridging should be done in such a manner as not to extrusions in symmetrical bundles, with proper band
cut into or otherwise notch the thermal barrier material to tension and paper interleaf to protect surfaces to ensure
provide maximum mechanical strength to the profile while dimensional stability. In addition, the bundles should be
removing all of the aluminum bridge to maximize thermal placed on the truck in such a way as to avoid excessive
performance. weight on the extrusions. Due to transporting across
different geographical/climatic regions, great temperature
7. The width of the debridging cut should range between fluctuations are likely to occur. Extreme cold or heat may
75% and 100% of the gap between the mechanical affect shock resistance and dimensional stability of the
interlocks. extrusions.
4.3.5 Handling, Care and Maintenance After removing the extrusions from the vehicle at the
Because of the unique properties of thermal barrier destination, a stabilization period should be observed to
materials and the different handling requirements in the bring the extrusions to room temperature. Once room
industry, this section will be divided into three separate temperature has been reached, follow the guidelines in the
areas: Handling in the Plant, Handling During Storage, and previous two sections, Handling in the Plant and Handling
Handling During Packing and Shipping. As in any During Storage.
industry, certain common practices apply; the following
statements could be used as a common guideline in all 4.4 Installation of Poured and Debridged Thermal
three categories: Barriers
1. The thermal barrier material needs time to develop its 4.4.1 Fabrication
proper physical properties. This time period may vary Generally, the fabrication operations which are performed
depending on specific formulations. on thermal barrier sections are the same as those which are
performed on conventional, non-thermally improved
2. After this period, the filled and debridged extrusions sections. These processes consist of punching, drilling,
should be handled per the suppliers recommendations. milling, sawing, shearing, curving, and straightening. The
designer must consider each section with the appropriate
operations in mind during initial product design. Whenever
possible, these operations should be done in areas of the

extrusion away from the thermal barrier cavity. If it dropped onto a hard surface or subjected to sudden impact
becomes necessary to perform one or more of these loads. If long lengths of material are handled either singly
fabrication operations in the cavity area, the following or in bundles, care should be taken to prevent excessive
issues should be addressed where appropriate: bending of the framing. More than a single load bearing
point may be required when using slings or cables when
1. Provide sufficient clearance for the tooling (punch head, shipping. Care must be exercised to prevent excessive
drill bit, milling head, etc.) to perform the desired operation distortions of the framing in bundles due to the use of
without marring or distorting the surrounding section. "chocker slings" or other handling devices. Assembled
frames should be unloaded and stored so as to prevent
2. Provide direct support on the back or underside of the racking or twisting. The stacking of material should be
section behind the thermal barrier cavity so that abnormal properly blocked and piles held to a limited height to avoid
deflections or stress concentrations do not occur, especially the application of excessive weight to the material.
during punching and shearing operations. Material which is received banded should be stored in this
3. Provide sufficient provision in the tooling design for chip manner until actual installation is begun. All framing
and slug removal. Thermal barrier materials can quickly products should be stored in an area free from traffic and
plug fabrication tooling if allowances are not made for other construction activities and out of direct exposure to
waste material removal. the sun and other elements.
4. Make provisions to prevent saw kick-back when cutting Care must be exercised when anchoring the framing to the
thermal barrier material along the length of the cavity as in surrounding structure. Because of possibly high impact
end notching. loading, power actuated fastener guns should not be used to
anchor thermal barrier extrusions especially in the cavity
5. Adjust the speed of operation, particularly punching, area. Proper shimming of anchors will prevent excessive
speed should be adjusted so as to minimize impact loading distortion of the framing as well as reduce the bending
stresses. stresses in the fastener. Whenever possible fasteners,
particularly perimeter anchors, should be located no closer
With the cautions listed above fabrication of thermal barrier than 75 mm (3 in) to the cut ends of the framing.
extrusions is not appreciably different than the fabrication
of non-thermally improved sections if the designer takes The use of excessive amounts of some solvents or
into account the properties of the thermal barrier materials cleansing agents to clean the thermal barrier sections prior
as well as the properties of the aluminum extrusions. In to or during glazing may cause deterioration of the
most cases common sense design and a knowledge of material. The installation contractor should check with the
fabrication tooling and operations are sufficient. The only manufacturer of the framing for recommendations for
real exception to this statement is in the curving or bending cleaning thermal barrier sections. The compatibility of
of thermally improved extrusions. sealants with thermal barrier compounds is another matter
which should be checked prior to application with either
Because of the unique distribution of stresses and the the framing manufacturer or the sealant supplier. As in the
possibility of excessive distortion, curving of thermally case of fabrication of thermal barrier framing, the use of
improved shapes should be approached with caution by the common sense and strict adherence to the guidelines
designer. Stress concentrations and distributions can vary furnished by the framing manufacturer will eliminate most
widely between a straight section and the same section installation problems before they can occur.
which has been curved. Factors such as the radius and
degree of curvature, the location of the thermal barrier 4.5 Manufacturing of Mechanically Locking Preformed
cavity, the specific formulation of the thermal barrier the Thermal Barriers
direction of curvature, the design function of the curved When inserting mechanically locking preformed thermal
piece and the allowable distortion after fabrication will barriers into aluminum extrusions, one should follow the
cause widely varying results. Often the easiest way to recommendations on the insertion equipment manufacturer
determine the effect of the combination of these factors is as well as the supplier of the thermal barrier. The
simply to have a test piece curved and then carefully manufacturing of mechanically locked preformed thermal
examined for evidence of excessive distortion or structural barriers can be separated into the following subjects:
failure. Occasionally design of a new section or pouring
after curving may be required for curved applications. 1. Knurling
2. Assembly
4.4.2 Job Site Storage/Handling 3. Crimping
Many problems that can occur with thermal barrier sections
at the job site can be eliminated by proper storage and The following sections will summarize generally
handling during installation. Whether stock length material acceptable procedures currently in use.
or fabricated and partially assembled framing, the sections
must not be abused. In no instance should the material be

UNKNURLED KNURLED
FIGURE 15
4.5.1 Knurling
1. Knurling – the notching of the aluminum cavity creating tiny points on the inside walls of the aluminum cavity.
(See Figure 15)
2. The knurling should be even on both sides of the aluminum cavity holding the thermal barrier in place.
3. The knurl should be as deep as possible, but not too deep resulting in a condition where the thermal barrier profiles cannot
be inserted into the aluminum cavities.
4. The knurling machine should be set up to follow all instructions as stated by the manufacturer of the insertion equipment.

FIGURE 16 – TYPICAL INSULATING STRUT THERMAL BARRIER PARTS
4.5.2 Assembly
The insulating struts are inserted into their cavities in both sections of the aluminum extrusions.
The result is one composite assembly consisting of the two separate aluminum extrusions and the thermal barrier profiles.
Assembly of the aluminum composite (2 aluminum extrusions and thermal barrier) can be done by two methods:
1. By hand
If inserting by hand, one needs to simply slide the thermal barrier profiles into their respective cavities in the aluminum
extrusions. As soon as the thermal barrier profiles are inserted the entire length of the aluminum extrusions, the aluminum
composite is ready for the crimping process.
2. Assembly Machine
While operating the Assembly Machine all the standard operating procedures from the equipment manufacturer should be
followed.
The equipment manufacturer will specify the configuration of the aluminum composite exiting the assembly process for transfer
to the crimping process.

4. The crimping machine can correct minor distortions
of the completed aluminum composite. Consult the
crimping machine instruction guide to correct minor
distortion of the aluminum composite during the
crimping process.
5. After completion of the crimping process, the

insertion process is complete. The aluminum
extrusions with the mechanically locking preformed
thermal barriers are complete, there is no setup, drying,
or curing time needed. The aluminum extrusions are
now ready to be manufactured in to the fenestration
product of choice.
While operating the crimping machine all the standard

operating procedures from the equipment
manufacturer should be followed.
4.5.4 Handling, Care, and Maintenance
4.5.4.1 Handling in the Plant

FIGURE 17 – CLOSE-UP PICTURE OF CRIMPED The Mechanically Locked Preformed Thermal Barriers
THERMAL BARRIER SECTION should be handled just as the individual aluminum
extrusions to prevent damage during handling. The
4.5.3 Crimping mechanically locked thermal barrier has no special
guidelines that need to be followed because of the
1. Crimping – the squeezing of the sidewalls of the aluminum insertion of the thermal barrier.
cavity to force the knurling on the inside walls of the aluminum
cavity to penetrate and lock the aluminum and the thermal 4.5.4.2 Handling During Storage
barrier into one assemble section. The thermal barrier extrusions should be stored and
handled to prevent damage to the finish on the
2. During crimping, one needs to be sure that the force crimping aluminum extrusions. One wants to make sure that no
the aluminum into the thermal barrier is even on both sides of cosmetic damage occurs to the extrusions so that they
the aluminum composite. The crimping machine will take care can be used in the field. Care must be taken when
of this if properly adjusted. extrusions are going to be stored in inventory.
Extrusions need to be protected from damage to the
3. One also needs to be sure that the crimping wheels are finish and distortion. Extrusions should be stored in
crimping the aluminum at the correct locations and squeezing symmetrical, banded bundles. Care must be exercised
the aluminum hammer into the thermal barrier. to ensure proper band tensioning and extrusions should
be interleaved with paper. It should also be noted that
putting excessive weight on these bundles can cause
distortion and other damage.
4.5.4.3 Handling During Shipping

The Mechanically locked Preformed Thermal barriers
should be handled during shipping just as they are
handled in the plant. They need to be shipped to avoid
damage to the finishes on the aluminum extrusions
during shipping.
FIGURE 18 – PICTURE OF ROLLING PROCESS

4.6 Installation of Mechanically Locked Preformed 4.6.2 Job Site Storage and Handling
Thermal Barriers Proper handling of the thermal barriers sections should be
followed as in the sections for poured and debridged
4.6.1 Fabrication thermal barriers Job Site Storage/Handling. Stock length
Generally, the fabrication operations performed on thermal material whether it be just aluminum extrusions or
barrier sections are the same as those performed on assembled sections with the thermal barrier should not be
conventional, non-thermally improved sections. These abused. In no instance should the material be dropped onto
processes consist of punching, drilling, milling, sawing, a hard surface or subjected to sudden impact loads. If long
shearing, curving, and straightening. The designer must lengths of material are handled either singly or in bundles,
consider each section with the appropriate operations in care should be taken to prevent excessive bending of the
mind during initial product design. Whenever possible, framing. More than a single load bearing point may be
these operations should be done in areas of the extrusion required when using slings or cables when shipping. Care
away from the thermal barrier. If it becomes necessary to must be exercised to prevent excessive distortions of the
perform one or more of these fabrication operations on the framing in bundles due to the use of "chocker slings" or
thermal barrier, the following issues should be addressed other handling devices. Assembled frames should be
where appropriate: unloaded and stored so as to prevent racking or twisting.
The stacking of material should be properly blocked and
1. Provide sufficient clearance for the tooling (punch head, piles held to a limited height to avoid the application of
drill bit, milling head, etc.) to perform the desired operation excessive weight to the material. Material that is received
without marring or distorting the surrounding section. banded should be stored in this manner until actual
2. Provide direct support on the back or underside of the installation is begun. All framing products should be
section behind the thermal barrier so that abnormal stored in an area free from traffic and other construction
deflections or stress concentrations do not occur, especially activities and out of direct exposure to the sun and other
during punching and shearing operations. elements.
3. Provide sufficient provision in the tooling design for chip Care must be exercised when anchoring the framing to the
and slug removal. Thermal barrier materials can quickly surrounding structure. Because of possibly high impact
plug fabrication tooling if allowances are not made for loading, power actuated fastener guns should not be used to
waste material removal. anchor thermal barrier extrusions especially in the cavity
area. Proper shimming of anchors will prevent excessive
4. Adjust the speed of operation, particularly punching, distortion of the framing as well as reduce the bending
speed should be adjusted so as to minimize impact loading stresses in the fastener. Whenever possible fasteners,
stresses. particularly perimeter anchors, should be located no closer
than 75 mm (3 in) to the cut ends of the framing.
With the cautions listed above fabrication of thermal barrier
extrusions is not appreciably different than the fabrication The use of excessive amounts of some solvents or
of non-thermally improved sections if the designer takes cleansing agents to clean the thermal barrier sections prior
into account the properties of the thermal barrier materials to or during glazing may cause deterioration of the
as well as the properties of the aluminum extrusions. In material. The installation contractor should check with the
most cases common sense design and a knowledge of manufacturer of the framing for recommendations for
fabrication tooling and operations are sufficient. The only cleaning thermal barrier sections. The compatibility of
real exception to this statement is in the curving or bending sealants with thermal barrier compounds is another matter
of thermally improved extrusions. which should be checked prior to application with either
the framing manufacturer or the sealant supplier. As in the
Because of the unique distribution of stresses and the case of fabrication of thermal barrier framing, the use of
possibility of excessive distortion, curving of thermally common sense and strict adherence to the guidelines
improved shapes should be approached with caution by the furnished by the framing manufacturer will eliminate most
designer. Stress concentrations and distributions can vary installation problems before they can occur.
widely between a straight section and the same section
which has been curved. Factors such as the radius and
degree of curvature, the location of the thermal barrier, the
direction of curvature, the design function of the curved
piece and the allowable distortion after fabrication will
cause widely varying results. Often the easiest way to
determine the effect of the combination of these factors is
simply to have a test piece curved and then carefully
examined for evidence of excessive distortion or structural
failure. Occasionally design of a new section may be
required.

In the past, thermal barrier extrusions were analyzed
5.0 ENVIRONMENTAL IMPACT assuming adhesion or other interlocking forces between the
aluminum and the barrier material. This composite action
5.1 Effect of the Environment on the Design results in a calculated moment of inertia that approaches
The effect of environmental conditions on thermal the theoretical I value of the exterior and interior aluminum
barriers should be considered in design, application and portions of the extrusions adjusted for shear deformation of
incorporation into fenestration products. the thermal barrier material itself. If a reduction in
adhesion due to thermal cycling occurs during the AAMA
The environmental conditions to be most concerned about 505 test, this shall be accounted for in calculations
on exterior building products are exposure to ultraviolet performed by a qualified engineer to ensure the system will
light, water immersion, high humidity, high temperature, not pose a safety hazard.
low temperature, thermal cycling and cyclic bending.
While each of these should be considered on its own, it The AAMA 505 thermal cycling test may reveal a
might be advisable to combine two or more when testing. condition called "shrink back" or “dry shrinkage”. This is a
condition where the thermal barrier shrinks back from the
5.1.1 UV Exposure end causing a potential for air and water leakage. This
All thermal barrier materials are resistant to structural cannot occur without a reduction in shear strength. See
degradation from UV exposure. Slight color change Section 4.1.3 for an explanation of dry shrinkage.
and/or surface crazing may be experienced, but this will
have little effect on the strength or impact resistance of the 5.1.5 Cyclic Bending
material. In cases where there will be full, direct, exposure This refers to the repeated stresses that will occur when a
to the sun, it would be advisable to verify the performance composite section is subjected to positive and negative
with the thermal barrier supplier. wind load reversals. Experience and testing have shown
that the thermal barrier materials currently being used are
5.1.2 Water Immersion and Humidity Resistance not adversely affected by this kind of action. If a material
Thermal strut materials and polyurethane materials based with a much higher modulus or a very low ultimate
on polyether polyols have adequate resistance to high elongation is being considered, cyclical flexure testing
humidity and the water immersion that would result from should be performed.
ponding in the sill members. Long term adhesion in
chemically bonded thermal barriers may be affected with 5.1.6 Compatibility with Sealants
prolonged ponding of water on the thermal barrier. Materials used for thermal barriers have a good record of
compatibility with all types of building sealants. For
5.1.3 Temperature Extremes compatibility, neither the sealant nor the thermal barrier
The extremes of temperature likely to be encountered in shall be adversely affected by the other. Manufacturers can
service will not degrade the thermal barrier material, but provide data on compatibility of materials presently in use.
both high and low temperatures will affect the properties Only new or untested materials need be tested for
while the material is at those temperatures. compatibility.
In general, temperatures encountered in normal fenestration 5.2 Effect of Thermal Barrier Materials on the
service applications, will not subject thermal barriers to Environment
structural degradation. These extremes include both high Thermal barrier materials can impact on the environment
and low temperature limits of the thermal barrier products. in several ways, both in the manufacturing process and
disposal. MSDS and Product Data sheets for the products
5.1.4 Thermal Cycling processed should be consulted and followed. Federal,
Alternate high and low temperatures may result in a State and local laws should be reviewed to determine
reduction of adhesion or degradation, at interfaces between proper processing and disposal for the thermal barrier
the poured and debridged type of thermal barrier, and the products being produced and handled.
aluminum and the finish coats. This is a result of the
difference in expansion and contraction rates between the
aluminum and the thermal barrier. The coefficients of
linear thermal expansion will help to determine whether or
not thermal cycling may case a loss in shear strength
To determine if this phenomenon is occurring in a specific

design, it is recommended that a thermal cycling test be
conducted in accordance with AAMA 505.

6.1.5.2 Report
6.0 TESTING The report shall include the following:
6.1 Thermal Barrier Material Properties 1. Density, to the nearest 1.6 kg/m3 (0.10 lbf/ft3).
6.1.1 Scope 2. Thickness, Height, Length and Weight.

This section covers the preparation of standard-size test
samples and basic tests to determine the physical properties 6.1.6 Specific Gravity
of thermal barrier materials (solid or cellular). The thermal Specific Gravity of regularly or irregularly shaped
barrier component supplier typically provides this data. materials shall be determined according to ASTM D792.
For pour and debridge quality checks at point of application
refer to AAMA QAG-1. For point of application quality 6.1.7 Tensile Properties
checks for other thermal barrier systems, refer to the
thermal barrier component manufacturer. 6.1.7.1 Determine the tensile strength and elongation
according to ASTM D638.
6.1.2 Significance
The following tests can be of value in comparing physical 6.1.7.2 The following test parameters are recommended:
properties of different materials. Material properties will The test specimen shall be a 19 mm wide by 6 mm thick
vary widely depending on the thermal barrier material used. (3/4 in wide by 1/4 in thick) sample and the crosshead
speed shall be 5 mm (0.2 in) per minute. Report the tensile
6.1.3 Description of Terms strength, elongation, any yield point, and % strain at the
The reader’s attention is drawn to the glossary in Appendix yield point if present.
7.6. It is essential that the terms used in the body of the
document be clearly understood if the document is to have 6.1.8 Hardness
full meaning. Determine the hardness in accordance with ASTM D2240
on the 6 mm (1/4 in) thick sample. Report the initial and a
6.1.4 Sampling of Poured Polyurethane 5 second drift value as determined on the top and the
bottom surfaces. If the determination is to be made at
6.1.4.1 Test samples can be made in any suitable mold. subnormal temperatures, condition the instrument at the
The following two sizes are recommended: 305 mm x 150 same temperature. To prevent moisture from damaging the
mm x 6 mm (12 in x 6 in x 1/4 in), and 305 mm x 150 mm instrument, it is advisable to place the tester directly in a
x 12 mm (12 in x 6 in x 1/2 in). desiccator after removing it from the cold box.
6.1.4.2 The procedures used to prepare the test sample 6.1.9 Compression Strength
relating to component ratios, temperature, mixing direction, Determine the compression strength in accordance with
mold temperature, and curing conditions shall conform to ASTM D695. Cut the specimen from the 12 mm (1/2 in)
the supplier's recommendations. sample, retaining the molded surfaces.
6.1.4.3 The test sample for reference purposes shall be 6.1.10 Impact Strength
allowed to age a minimum of 7 days before testing at 24°C Determine the notched Izod impact properties in
±6°C (75°F ±10°F). accordance with ASTM D256 on the 12 mm (1/2 in)
sample with the mold surface in accordance with either
6.1.5 Density method A or B.
6.1.5.1 Procedure 6.1.11 Flexural Modulus

Section density can be determined on any thickness of
molded material. The minimum specimen length shall be 6.1.11.1 Determine flexural modulus, using the general
12 mm (1/2 in). Weigh and measure the specimen to procedure in ASTM D790, Method I.
within ±1% of the value to be determined. Calculate the
density as follows: 6.1.11.2 The following test parameters are recommended
for thermal plastic materials:
W
DENSITY = (kg/m3)
V 1. Specimen size - Length 75 mm ± 0.5 mm (3.0 in ± 0.02
in), Width 25 mm ± 0.5 mm (1.0 in ± 0.02 in) and thickness
Where: 6.4 mm ± 0.2 mm (0.250 in ± 0.01 in).
W = mass of specimen, kg
V = volume of specimen, m3 2. Span - 50 mm (2 in).
3. Rate of Crosshead Motion - 0.20 mm/sec ± 0.02 mm/sec

(0.50 in/min ± 0.05 in/min).

4. Calculation - Calculate the tangent modulus of elasticity. as impact strength, creep resistance, resistance to UV,
See Section 11.11.1 of ASTM D790. humidity, ozone and retention of bond strength. While not
normally used in engineering calculations, this second
NOTE #1: When calculating slope, use the steepest tangent group is none-the-less significant in determining the
as shown in Figure 1 of ASTM D790. fabricating qualities of extrusions and their long term
performance in the environment.
NOTE #2: The crosshead rate of 0.2 mm/sec (0.50 in/min)
differs from the rate of 0.02 mm/sec (0.05 in/min) specified Successful extrusion design requires knowledge of the
in D790. Test data has shown that the faster rate provides basic structural properties of the thermal barrier composite.
a lower coefficient of variation than does the slower rate. Moment of inertia (second area moment) is important
because it is a measure of stiffness and, hence, of the
5. Condition a specimen at the test temperature for a deflection under load of the composite. In particular it is
minimum of 30 minutes before testing. desirable to know if the connection between the
6.1.12 Thermal Conductivity semi-sections of the extrusion can be characterized as slip-
Determine the thermal transmission properties according to resistant (i.e., little or no slipping between sections) and
ASTM C177 or C518. Depending upon the size stiff (i.e., very little distortion due to shear force). If it is a
requirement of the tester, special samples may need to be slip-resistant and stiff connection, then the effective
prepared. [The minimum recommended size is 305 mm x moment of inertia will be higher than if the connection is
305 mm (12 in x 12 in)]. The manufacturer shall specify not and a more cost-effective design can be achieved.
the mean temperature and Delta T. In many window and door designs much of the load is
6.1.13 Thermal Expansion carried in shear in members designed to resist bending.
Determine the coefficient of thermal expansion according Thus, shear strength of the thermal barrier composite is a
to ASTM D696 using the 3 mm (1/4 in) thick sample. This significant consideration.
test specifies a temperature range of -66°C to 30°C (-86°F Tensile loads on the thermal barrier material also occur
to 86°F); a broader temperature range may be tested, frequently, especially as a consequence of negative wind
however the results may not be linear. pressure. Torsional loads are placed on the thermal barrier
6.1.14 Heat Deflection Temperature material either as a direct function of design considerations
Determine the deflection temperature according to ASTM or as a result of gasket pressures in dry glazing systems.
D648 applying 455 kPa (66 psi) on the 12 mm (1/2 in) The reader may refer to Appendix 7.5 for a method to
specimen. The load shall be applied to the surface not in calculate design values for effective moment of inertia (I'e),
contact with the mold. effective section modulus (Se) and core shear for a thermal
6.2 Composite Performance barrier composite. The beam span, section properties of
Thermally improved framing members typically consist of each aluminum component, load type (uniform,
two aluminum sections joined together along their lengths concentrated, triangular or trapezoidal), cavity dimensions
by a thermally insulating material. Poured and debridged and the shear modulus of the thermal barrier are needed for
and mechanically crimped in place thermal barriers are two input.
commonly used designs to improve the thermal efficiency Thermal barrier properties may be temperature dependent.
of aluminum fenestration products. For poured and Thus the beam's design properties must be evaluated with a
debridged designs, the insulating material is usually shear modulus value corresponding to the highest
polyurethane in composition and is poured in place over a appropriate temperature expected at the mid-depth of the
thin metal bridge that temporarily connects the sections thermal barrier. See Section 6.5 and note that the average of
together. This bridge is later removed by cutting or sawing the metal temperatures of the exterior and the interior sides
after the thermal insulation has hardened sufficiently to of the window frame may be conservatively taken as the
permit handling of the extrusions. In its final form the average thermal barrier temperature.
filled and debridged extrusion is in essence a composite
structure. (See Figures 1 and 2). Mechanically crimped A CD of the design method in Appendix 7.5 has been
thermal barriers are assemblies which are comprised of included with this TIR which contains a Windows
thermal barrier struts and aluminum extrusions joined compatible program of this design method and a program
together mechanically. They are also considered composite User’s Guide. This makes the method practical for quick,
assemblies. (See Figure 8). The kinds of tests required to simple and suitably accurate evaluation of composite
determine the performance of thermal barrier extrusions properties for many shapes and sizes of extrusions. The
can be divided into two groups. The first group consists of method is based on original research done by John A.
structural properties such as bending strength, shear Hartsock, 619 Sater Lane, Edmonds, WA 98020. Mr.
strength, tensile strength and torsional strength. These are Hartsock may be contacted for additional programming
the kinds of properties normally required in engineering beyond the scope of this report.
calculations. The second group consists of properties such

Comparison testing of entire product lines, one against
another, is seldom done due to the high cost of testing.
Suppliers and manufacturers of thermal barrier products
generally publish complete data on the performance levels
that can be expected from their products. This information
is usually sufficient to evaluate and select the optimum
product for a particular installation. The cost-conscious
user of architectural framing specifies mock-up testing only
when unique or special job conditions warrant the cost of
additional testing.
6.4 Testing Procedures

There are many procedures that can be used to test thermal
barrier products and materials. AAMA has developed
testing procedures for flexural, tensile, shear and torsional
testing of thermal barrier composites. These procedures are
outlined in the Appendices of this TIR along with other
procedures for testing thermal barrier compounds. The
FIGURE 19
procedures given are those that were used to develop the
The AAMA Test Extrusions were developed to provide the test data and background information presented in other
AAMA Thermal Barrier Structural Systems Task Group sections of this TIR. (Refer to Sections 7.2, 7.3 and 7.4).
with useful and adaptable test samples at a minimal amount
of cost, for promulgation of viable test procedures and 6.5 Temperature Concerns
parameters. The modified I-beam is easily gripped in Many factors affect the temperature of architectural metals.
fixtures for structural tests. Webs and/or flanges can be Ambient air temperatures tend to determine the lowest
removed by sawing, to change the moment of inertia and experienced metal temperatures. However, the highest
location of the thermal barrier with respect to the neutral temperatures experienced by the metal may be significantly
axis. They also provide a "standard" cavity for thermal higher than the highest ambient air temperatures. This
barrier material suppliers' evaluation of various phenomenon is primarily attributable to the absorption of
polyurethane formulations "in place". The AAMA Test radiant energy from the sun by exposed metal surfaces.
Extrusions are NOT representative of typical thermal The amount of radiant energy absorbed is affected by the
barrier window shapes, were NOT intended for verification color of the metal surface, shading of the metal and the
of product performance, and should NOT be used as such. angle of incidence of the sun's rays on the exposed surface.
Manufacturers' standard extrusion shapes and cavity Dark surfaces that are unshaded and on the sunny side of
configurations in general make the most appropriate the building will experience surface temperatures much
samples for this type of testing. higher than ambient air temperatures. Conversely, metal
that is light colored and shaded may reach surface
6.3 Comparative Testing temperatures only slightly higher than ambient air
There are many reasons for testing products with thermal temperatures. Since most thermal barrier systems are
barriers. Testing can be performed to verify composite designed to glaze insulating glass units, the inside metal
performance as outlined above. Testing can also be used as surfaces will experience a considerably smaller temperature
a means of comparing various aspects of the design of range than the exterior faces of the framing. In addition, if
thermal barrier products. If the designer is interested in the glass is coated with a reflective or Low-E coating, the
evaluating different thermal barrier materials, he may inside metal is shaded as well as insulated from the sun's
choose to perform a series of tests using a standard cavity radiant energy. Under these conditions, inside metal
such as the AAMA test extrusion filled with different surface temperatures may vary little from ambient room
barrier materials under various testing conditions. This temperature in occupied buildings. In composite thermal
would be very useful in ascertaining which thermal barrier barrier systems, the differential temperature between the
compound or design best fits the design conditions. interior and the exterior metal may cause the framing
members to deflect. For example, on a hot day, the exterior
Another type of comparison might be obtained by testing will tend to expand more than the interior creating an
several prospective cavity designs utilizing the same outward deflection. Conversely, on a cold day, when the
thermal barrier compound or design. This type of testing is exterior metal is much colder than the interior metal the
very helpful in optimizing cavity design for the anticipated framing member will tend to deflect inward. These
design service conditions. Normally, the manufacturer deflections result in additional shear stresses in the thermal
does this type of testing during the initial development of a barrier that are similar to the shear stresses caused by wind
new product. loads. Thermal deflections and stresses may be additive or
help cancel out deflections and stresses caused by wind
loads.

Consideration should be given to these deflections and external face will be much closer to ambient air
stresses during the design of a project. Refer to temperature than when there is no wind. The temperature
ASHRAE’s Handbook of Fundamentals for Heating and on the interior surface is difficult to predict but it will
Wind Design Conditions for various portions of the United sometimes reach a temperature in excess of 11°C (20°F)
States, Canada and other World Locations. It is very above ambient depending on interior conditions such as
unlikely that these temperature extremes will correspond drapes, blinds and recesses. This moderates the effect of
with the maximum design wind loads; therefore when radiant energy on the temperature gradient through the
combining these loads it is generally acceptable to apply a framing. This effect should also be of prime concern to the
combined load reduction factor. design professional when analyzing the appropriateness of
a particular framing application.
The flow of energy in a thermal barrier composite section
must also be considered. This flow is greatly affected by 6.5.1 Thermal Performance Factors
the surface area to mass ratio of both the interior and
exterior exposed framing members. Therefore, even When choosing a particular framing system, the design
though an exposed exterior face may become very hot from professional should address the following minimum set of
radiant energy in still air, if the mass is relatively low factors affecting thermal performance:
compared to the exterior surface area it will tend to cool 1. What is the color of the framing?
very rapidly convectively when the wind blows. This is 2. Where is the glazing located with respect to the depth of
particularly true of a material with high thermal the frame?
conductivity such as aluminum. This means that when a 3. Where is the thermal barrier located with respect to the
wind load is applied to the framing, the temperature of the depth of the frame?
TEMPERATURE CONCERNS CHART

Condition SUMMER WINTER
Any Inside Metal with Coated/Insulating Glass IAA + {11°C (20°F)} to IAA - {11°C (20°F)} to
1
IAA + {17°C (30°F)} IAA - {6°C (10°F)}
Any Inside Metal with Clear/Insulating Glass IAA + {17°C (30°F)} to IAA - {28°C (50°F)} to
2
IAA + {22°C (40°F)} IAA - {6°C (10°F)}
Any Inside Metal with Coated/Monolithic Glass IAA + {28°C (50°F)} to IAA - {11°C (20°F)} to
3
IAA + {33°C (60°F)} IAA - {6°C (10°F)}
Any Inside Metal with Clear/Monolithic Glass IAA + {39°C (70°F)} to IAA - {11°C (20°F)} to
4
IAA + {44°C (80°F)} IAA - {6°C (10°F)}
Any Outside Metal which is Shaded with Any Glazing OAA + {6°C (10°F)} to Equal to OAA
5
OAA + {11°C (20°F)}
Any Outside Metal with a Light or Reflective Coating OAA + {17°C (30°F)} to Equal to OAA
6
with Any Glazing OAA + {22°C (40°F)}
Any Outside Metal with a Medium Shade Coating with OAA + {22°C (40°F)} to Equal to OAA
7
Any Glazing OAA + {28°C (50°F)}
Any Outside Metal with a Dark or Black Coating with OAA + {28°C (50°F)} to Equal to OAA
8
Any Glazing OAA {33°C + (60°F)}
TABLE 1
4. Is the glazing material insulated?

5. Is the glazing material coated with a reflective film?
6. What is the orientation of the framing with respect to the sun?
7. Is the glazing system shaded by an overhang or shrubs and for what period of time?
8. What will be the ambient air temperature(s) on the inside of the occupied building?
9. What is the lowest outside air temperature for the building location from past climate data?
10. What is the highest outside air temperature for the building location?
11. Is the climate predominately sunny or predominately cloudy?
12. Will the building be exposed to gusting winds?
13. Has the proposed system been tested for the expected conditions listed above?
14. Are there any special conditions or factors that may adversely affect the performance of the product?
15. What is the CRF (Condensation Resistance Factor) of the proposed system?
16. What is the Thermal Transmittance (U Value) of the proposed system?
17. What is the Solar Heat Gain Coefficient (SHGC) of the proposed system?
18. Are there insulated spandrel areas included in this installation?

After all of the applicable factors have been determined, the The outside thermal range (hottest summer outside surface
designer can delineate the appropriate thermal performance temperature to coldest winter outside surface temperature)
specifications. would be:
6.5.2 Guidelines OSR = 63°C – (-32°C) = 95°C (171°F)

The following guidelines were derived from the
experiences of and the testing done by the members of The thermal barrier temperatures (average of hottest inside
AAMA, the National Research Council of Canada, the and hottest outside surface temperatures) would be:
American Society of Heating, Refrigeration and Air TBTS = (38°C + 63°C)/2 = (101°C)/2 = 50.5°C (123°F) in
Conditioning Engineers and other sources involved in the summer.
glazing industry and related fields. They should not be
construed as absolutes but rather as guidelines to assist the TBTW = [15°C + (-32°C)]/2 = (-17°C)/2 = -8.5°C (17.5°F)
design professional who will make the ultimate in winter.
specifications decision based on knowledge and
experience. The temperature range for the thermal barrier material
would be:
6.5.3 Examples TBR = 50.5°C to -8.5°C or a range of 59°C (105.5°F)
The following examples indicate the method of
determining the approximate surface temperatures for 6.5.3.2 Example #2:
various geographical locations:
Location: Seattle, Washington
6.5.3.1 Example #1: Ambient outside air temperature (OAA): -16°C (3°F) in the
winter, 37°C (98°F) in the summer.
Location: Indianapolis, Indiana
Ambient outside air temperature (OAA): -32°C (-25°F) in Building is glazed on the north and west sides and oriented
the winter, 41°C (106°F) in the summer. with one axis northeast to southwest and the other axis
northwest to southeast. The framing will be light bronze
Building is glazed on all four sides and oriented with one anodized (Condition 7) with clear insulating glass
axis north to south and the other axis east to west. The (Condition 2). The glazed openings are shaded under a 2 m
framing will be clear anodized (Condition 6) with reflective (6 ft) overhang with coniferous ground shrubs. Tempered
insulating glass (Condition 1). Tempered air inside the air inside the building will be maintained at approximately
building will be maintained at approximately 21°C (70°F) 18°C (65°F) in the winter and 24°C (75°F) in the summer
both winter and summer (IAA). (IAA).
From Table 1, the inside surface temperatures (Condition From Table 1, the inside surface temperatures (Condition
1) would be: 2) would be:
ISTS = IAA + (11°C) to IAA + (17°C) = (21°C + 11°C) to ISTS = IAA + (17°C) to IAA + (22°C) = (24°C + 17°C) to
(21°C + 17°C) = 32°C to 38°C (90°F to 100°F) in summer. (24°C + 22°C) = 41°C to 46°C (105°F to 115°F) in
ISTW = IAA – (11°C) to IAA – (6°C) = (21°C - 11°C) to summer.
(21°C - 6°C) = 10°C to 15°C (50°F to 60°F) in winter. ISTW = IAA – (28°C) to IAA – (6°C) = (18°C - 28°C) to
(18°C - 6°C) = -10°C to 12°C (15°F to 55°F) in winter.
From Table 1, the outside surface temperatures (Condition
6) would be: From Table 1, the outside surface temperatures (Condition
OSTS = OAA + (17°C) to OAA + (22°C) = (41°C + 17°C) 7) would be:
to (41°C + 22°C) = 58°C to 63°C (136°F to 146°F) in OSTS = OAA + (22°C) to OAA + (28°C) = (37°C + 22°C)
summer. to (37°C + 28°C) = 59°C to 65°C (138°F to 148°F) in
OSTW = Equal to OAA = -32°C (-25°F) in winter. summer.
OSTW = Equal to OAA = -16°C (3°F) in winter.
The inside thermal range (hottest summer inside surface
temperature to coldest winter inside surface temperature) The inside thermal range (hottest summer inside surface
would be: temperature to coldest winter inside surface temperature)
ISR = 38°C – 10°C = 28°C (50°F) would be:
ISR = 46°C – (-10°C) = 56°C (100°F)

The outside thermal range (hottest summer outside surface The inside thermal range (hottest summer inside surface
temperature to coldest winter outside surface temperature to coldest winter inside surface temperature)
temperatures) would be: would be:
OSR = 65°C – (-16°C) = 81°C (145°F) ISR = 62°C - 13°C = 49°C (90°F)
The thermal barrier temperatures (average of hottest inside The outside thermal range (hottest summer outside surface
and hottest outside surface temperatures) would be: temperature to coldest winter outside surface temperature)
would be:
TBTS = (46°C + 65°C)/2 = (116°C)/2 = 55.5°C (131.5°F)
in summer. OSR = 81°C – (-9°C) = 90°C (163°F)
TBTW = [12°C + (-16°C)]/2 = (-4°C)/2 = -2°C (29°F) in Since the designer has decided to use an altered outside
winter. summer surface temperature for this project, his
specification would produce an outside surface
The temperature range for the thermal barrier material temperature range of:
would be:
OSRP = 88°C – (-9°C) = 97°C (174°F)
TBR = 55.5°C to -2°C or a range of 57.5°C (102.5°F)
The thermal barrier temperatures (average of hottest inside
6.5.3.3 Example #3: and hottest outside surface temperatures) would be:
Location: Phoenix, Arizona TBTS = (62°C + 81°C)/2 = (143°C)/2 = 71.5°C (162°F) in
Ambient outside air temperature (OAA): -9°C (16°F) in the summer.
winter, 48°C (119°F) in the summer.
Since the designer has decided to use an altered outside
Building is glazed on all four sides and oriented with one summer surface temperature for this project, his
axis north to south and the other axis east to west. The specification would produce a thermal barrier temperature
framing will be black anodized (Condition 8) with clear of:
monolithic glass (Condition 4). Tempered air inside the
building will be maintained at approximately 24°C (75°F) TBTSP = (62°C + 88°C)/2 = (150°C)/2 = 75°C (167.5°F) in
in the winter and 18°C (65°F) in the summer (IAA). summer.
TBTW = [18°C + (-9°C)]/2 = (9°C)/2 = 4.5°C (40.5°F) in
NOTE: Because the southern exposure is next to a highly winter.
reflective surface (the swimming pool), the designer may
wish to increase the outside summer surface temperature. The temperature range for the thermal barrier material
The winter outside surface temperature would be would be:
unaffected because at -9°C (16°F) the pool would either be
drained or covered. A summer outside surface temperature TBR = 71.5°C to 4.5°C or a range of 67°C (121.5°F).
of 88°C (190°F) will be used for this example.
Since the designer has decided to use an altered outside
From Table 1, the inside surface temperatures (Condition summer surface temperature for this project, his
4) would be: specification would produce a thermal barrier temperature
range of:
ISTS = IAA + (39°C) to IAA + (44°C) = (18°C + 39°C) to
(18°C + 44°C) = 57°C to 62°C (135°F to 145°F) in TBR = 75°C to 4.5°C or a range of 70.5°C (127°F).
summer.
The examples above indicate how the factors mentioned
ISTW = IAA – (11°C) to IAA – (6°C) = (24°C - 11°C) to earlier can affect the required performance of the thermally
(24°C - 6°C) = 13°C to 18°C (55°F to 65°F) in winter. broken framing system. It is up to the person writing the
thermal specifications for the installation to clearly outline
From Table 1, the outside surface temperatures (Condition the applicable factors and intelligently interpret the manner
8) would be: in which these factors impact thermal specifications. Only
OSTS = OAA + (28°C) to OAA + (33°C) = (48°C + 28°C) in this manner can poorly written, incomplete or unrealistic
to (48°C + 33°C) = 76°C to 81°C (169°F to 179°F) in thermal specifications be avoided.
summer. (The designer has chosen to use an outside surface
temperature of 88°C (190°F) for this project.
OSTW = Equal to OAA = -9°C (16°F) in winter.

The examples provided approximate cases with a low solar effect, with a moderate solar effect and with an extreme or severe
solar effect on the temperature of the thermal barrier material. The table below summarizes the results:
RESULTS OF THERMAL ANALYSIS

Solar Exposure Project Conditions Thermal Barrier Temperature
Clear anodized framing with reflective insulating glass in
Low (Example #1) 50.5°C (123°F) to -8.5°C (17.5°F)
Indianapolis, Indiana.
Light Bronze anodized framing with shaded clear
Moderate (Example #2) 55.5°C (131.5°F) to -2°C (29°F)
insulating glass in Seattle, Washington.
Black anodized framing with clear monolithic glass in
Severe (Example #3) 71.5°C (162°F) to 4.5°C (40.5°F)
Phoenix, Arizona.
Altered Severe Black anodized framing with clear monolithic glass next to
(Example #3 with a reflecting pool in Phoenix, Arizona. (Architect has 75°C (167.5°F) to 4.5°C (40.5°F)
modification) specified higher outside metal temperatures.)
TABLE 2
6.6 Testing Temperatures cost of testing standpoint. If the manufacturer has

The temperatures, temperature ranges and thermal performed this minimum amount of testing and provides
guidelines given above are very useful to those selecting or this data to the product user or specifier, then it is doubtful
specifying thermally broken framing systems. They can that job testing for thermal performance would serve any
also be of considerable use to manufacturers of framing useful purpose. Only in situations where anticipated field
systems and suppliers of system components. Suggested conditions exceed the temperature extremes tested would
test methods for determining the bending, tensile, shear and additional testing be appropriate.
torsional properties of thermally broken sections are given
in the Appendix of this TIR. Since the properties being 6.7 Safety Factor
tested may vary widely with temperature, it is paramount The average values from testing are divided by an
that appropriate testing temperatures be determined prior to appropriate safety factor to determine the allowable
testing. values used for structural design of the composite
member. The following recommendations and discussion
Test data should be obtained at enough different are based on a study of the safety factor for longitudinal
temperature settings to adequately represent the field shear strength. This study considered a procedure in the
conditions under which the design will perform. A Aluminum Association’s specifications (Section 8.3) and
minimum number of thermal test points would represent test data for six sets of 20 specimens each. Each set used a
room temperature, 24°C (75°F), and the highest different combination of cavity finish and polyurethane
temperature which the thermal barrier material would barrier. A recommended safety factor of 2.5 is given in
experience under field conditions as outlined in the AAMA 505.
guidelines given above. A complete temperature profile
would include test data at -18°C (0°F), room temperature, The value of 2.5 for the safety factor, for longitudinal
24°C (75°F), 60°C (140°F) and 71°C (160°F) as measured shear strength, has been found to be appropriate for
at the thermal barrier. The first temperature range would products with a coefficient of variation (Cv) not exceeding
be appropriate during product testing while the second 11.9%. If a product (with a particular combination of
range would be more useful during product development. cavity surface finish, specific thermal barrier type, etc.)
has a Cv greater than 11.9%, then the required safety
The selection of temperature criteria for testing purposes factor, but not less than 2.5, is to be computed using
should be done with caution and due consideration of the Section 8.3.2 of the "Specifications for Aluminum
cost of testing. Care should be exercised that the test Structures; Allowable Stress Design" (7th edition) by the
results are derived from testing done under conditions as Aluminum Association.
close to anticipated field conditions as possible. If in
doubt, use the guidelines offered above or consult qualified The value of 11.9% is based in part on review of six sets
engineering personnel. It is usually desirable to evaluate of data (for variations and trends), but more generally on
the performance of several composite designs and materials Section 8.3.1 of the aluminum specifications. This value
during product development. Therefore a wider range of is based on the use of a 1.5 load factor to calculate a value
test temperatures and the concurrent increased cost of of 0.6 (= 1.5 / 2.5) for the under-capacity factor (φ), and a
testing is justified. statistical coefficient K of 3.37 for 18 specimens. The
nominal value of strength Sn is considered to be the
However, once the design and materials have been average Xm . The value 0.6 is then substituted in Equation
finalized, only those test temperatures representing the 8.3.1-1, written in terms of Cv and φ:
extremes of product thermal exposure are justifiable from a

Xa = Xm – K Sx = φ Sn = φ Xm Some interpretation is needed to use Section 8.3.2 and
engineers may differ on exactly what values to use for the
Φ Xm / Xm = (Xm – K Sx) / Xm = 1- K Cv = φ = 0.6 formula in that section of the Aluminum Association
specifications. If one uses β0 equal to 3.5 (connections),
Cv = (1-0.6) / 3.37 = 0.1187 VF equal to 0.05 (structural members) and Vp (same as
Cv) equal to 0.1196, then Eq. 8.3.2-1 predicts a required
Both sides of Eq. 8.3.1-1 have been divided by Xm so as safety factor of 2.5002. Thus this approach supports the
to get the equation in terms of φ and Cv . The calculated use of 11.9% for Cv since 0.1196 is greater than 11.9%.
value is of Cv is 11.87%. This approach has some conservatism in it but much less
so than using VF of 0.15 for welded connections.

7.0 APPENDICES
7.1 Cross Section Die Profile
AAMA TIR-A8-04
FIGURE 20 – AAMA DIE PROFILE DRAWING FOR POURED & DEBRIDGED AND MECHANICALLY CRIMPED IN PLACE TEST CAVITIES
Page 29
7.2 Flexural Test encountered under actual field conditions will normally
result in the smallest moment of inertia of the composite.
7.2.1 Scope For this reason, the effective moment of inertia derived in
the lab shall be calculated from test results that closely
7.2.1.1 This test method shall be used to determine the simulate the maximum anticipated field temperatures of the
effective moment of inertia (effective second area moment) thermal barrier material. While temperatures on the
of aluminum/elastomeric composites, and complex exterior surfaces of aluminum building products can reach
sections, in lieu of calculations. This test method shall also 82°C (180°F) for dark colors, maximum wind loads will
be used to determine “effective” shear modulus as defined not occur when these high temperatures are experienced
in Section 7.5.3.1. because air movement will cool the aluminum to near
ambient levels. It is therefore reasonable to assume that the
7.2.1.2 In general, the theoretical moment of inertia (I) of a maximum wind loads will not occur when the exterior
composite (assuming the aluminum sections are "fixed" in surface of the thermal barrier sections is over 49°C
relation to each other; i.e., no shear deformation is (120°F).
included) will be greater than the effective moment of
inertia (Iet) determined by this procedure. This test is If this method is used to find the effective shear modulus
designed as a useful method of determining apparent (Gc) of the thermal barrier, or to compare the test value of
effective moment of inertia. effective moment of inertia (Iet) to a theoretical value with
shear effects (Ie or I'e; Section 7.5), then measurements of
7.2.1.3 This test procedure may be used either to evaluate actual widths, thicknesses and depth of the composite are
the performance of a specific thermal barrier material or to needed. The actual measurements would be used to
evaluate the performance of a particular thermal barrier determine input for the procedure in Section 7.5.
material and extruded aluminum shape as a composite, or a
combination of the above. An aluminum composite section 7.2.1.5 The test method subjects the composite specimen to
is defined as: a small deflection from a concentrated load at the center of
the span. The specimen is loaded as a simply supported
COMPOSITE SECTION - Any combination of beam. Care must be taken to avoid eccentric loading that
aluminum and one or more non-metallic materials such as could result in rotation. It is assumed for the purposes of
elastomers, polyurethane, plastics, vinyl, etc. which are this test method that stresses will remain within the elastic
used as a thermal barrier joining the aluminum sections. range of the materials, the restraints provided at the
The components of this structure act together in such a supports simulate a simply supported end condition and the
manner that their joint structural performance is greater modulus of elasticity of the composite section remains
than the performance of the sum of the individual approximately equal to that of aluminum 68.9 x 106 kPa
components acting separately. (10 x 106 psi).
7.2.1.4 This test procedure is subject to several limitations: 7.2.1.6 By accurately measuring the concentrated load
applied and the resulting center deflection, the effective
1. The effective moment of inertia is only valid within the moment of inertia for the composite section can be
elastic range of the composite section. The effective determined by using the standard deflection formula for a
moment of inertia is, in general, exactly correct only for the simply supported beam with a concentrated load at the
span and type of loading used in the test. It is approximate center. Solving for the effective moment of inertia:
for other loading types (e.g., distributed vs. concentrated)
and span values. Under certain physical circumstances the PL3
thermal barrier material may reach its yield or even Iet =
48E∆
ultimate strength before the aluminum. Factors such as
temperature, cavity location and thermal barrier material
Where:
selected will all affect the results of the procedure. The
Iet is the effective moment of inertia for the composite
section being tested may behave in the field consistent with
section, based on testing.
a smaller moment of inertia than the effective value
P is the applied concentrated load at midspan.
calculated in the lab. Care must be exercised that the test
L is the length of the span between reaction points.
results are derived from testing done under conditions as
close to field conditions as possible. If in doubt, consult ∆ is the deflection of the center of the span due to the
qualified engineering personnel. applied load.
E is the modulus of elasticity for aluminum.
2. The structural performance of many thermal barrier
materials is very temperature dependent. Specifically, the
modulus of elasticity decreases with increasing
temperatures (the material becomes softer). Therefore the
highest temperature of the thermal barrier material

7.2.2 Procedure 7.2.2.3 Testing equipment shall be calibrated in accordance
with ASTM test method E529, Paragraph 9. If a testing
7.2.2.1 The test specimen shall be supported at the reaction machine is used, the speed of loading shall be 5 mm (0.200
points by a knife edge or a round rod. Free rotation of the in) per minute ±50%.
specimen in the plane of the loading shall be permitted.
7.2.2.4 Deflection shall be measured and recorded to the
7.2.2.2 Loads shall be applied so as not to permanently nearest 0.03 mm (0.001 in) absolute. Deflection shall be
distort the specimen or cause it to pass the elastic yield measured at the center of the span and at each end support.
point. This may be accomplished by restricting the span of The sum of the deflections at the supports shall be averaged
the specimen to a maximum (Lm) and limiting the load: and subtracted from the center deflection to get an overall
net deflection of the beam. Deformation shall be
12 Ehn Rt0.5 determined both after the completion of load application
L≤
175 Fty and after the load has been maintained for five minutes.
Care shall be taken to ensure that the deflection does not
4 FtyIRt exceed the ratio L/175.
P≤
Lhn
7.2.2.5 Permanent deformation of the specimen shall not
These formulae assume the composite remains within the exceed 0.2% of the clear span between supports. If this
elastic limit of the aluminum and that the maximum value is exceeded 15 minutes after the load has been
deflection will not exceed L/175 (a standard architectural removed, the test results shall be discarded, the failure
aluminum deflection limit). Specimen lengths shorter than recorded and the test rerun on a new specimen at a reduced
L when subjected to load P will result in deflections less load.
than L/175.
7.2.3 Test Cycles
Where:
7.2.3.1 The load P may be increased from zero to
L is the distance between the support points in millimeters maximum P in any convenient increments but a minimum
(inches). of 5 data points shall be obtained at zero, 1/4 P, 1/2 P, 3/4 P
E is the modulus of elasticity for aluminum. It equals 68.9 and maximum P. After preliminary establishment of an
x 106 kPa (10 x 106 psi). average effective moment of inertia it may be desirable to
test a limited number of specimens at a greater number of
hn is the distance from the center of gravity of the section load levels to increase the statistical significance of the
being tested to the farther of its extreme fibers. Thus n = 1 results. Further testing would be indicated if one or more
or 2, as shown in Figure 28 in Section 7.5.8. An initial of the test results deviates from the average by greater than
estimate of one-half the composite's depth is acceptable if ±5%.
more exact section property information is not available.
However, if this estimate is used it is suggested the test be 7.2.3.2 Test data shall be obtained at ambient conditions
run at a series of gradually increasing loads and the results that adequately represent the field conditions under which
plotted to ensure the test is being conducted within the the design will perform. Temperatures of the test room,
elastic range of the composite. thermal barrier material and heated section of the aluminum
Fty is the specified minimum yield stress. The value for extrusion shall be recorded if applicable.
6063-T5, a commonly used grade of aluminum, is 110,316
kPa (16,000 psi). Note: 1 kPa = 0.001 N/mm2. 1. The test specimen may be most conveniently heated with
an electric heat tape. The heat tape shall be applied to the
I is the calculated moment of inertia of the unpoured test exterior face of the aluminum extrusion. Thermocouples
specimen in mm4 (in4). This is an upper bound on the shall be located under the heat tape, imbedded in the center
effective moment of inertia (Ie or I'e in Section 7.5) of the of the thermal barrier material and on the surface of the
composite. interior face of the aluminum extrusion. (See Figure 21)
P is the maximum permissible load, which meets deflection The thermo-couple on the exterior face shall be used to
and stress limits, in Newtons (pounds) control the temperature at which the test is conducted. The
thermocouple imbedded in the thermal barrier material
Rt is a reduction factor to account for stress and deflection shall be the used to determine that stabilization has
increases, due to shear deformation of the thermal barrier occurred before the test is conducted. The thermocouple
(core). A value of 0.9 is suggested for many cross-sections, on the interior face will be used to determine the
not for final design but solely for this test procedure. temperature difference across the specimen. All three
thermocouple readings shall be recorded in the test report.

CENTERLINE OF SHAPE
AND CENTERLINE OF
LOAD APPLICATION
C
L HEAT TAPE FOR HEATING
SHAPE WITH LENGTH
AS REQUIRED
HOLD IN PLACE
WITH DUCT TAPE
CARDBOARD SHIELD FOR
THERMOCOUPLE 1.575 mm
(0.062 in) THICK MINIMUM
SHAPE BEING
TESTED
CONTROLLING
THERMOCOUPLE
FOR HEAT TAPE
SET TO DESIRED
SURFACE TEMPERATURE
STABILIZATION THERMOCOUPLE IN THE

MIDDLE OF THE THERMAL BARRIER MATERIAL
C
L
THERMOCOUPLE USED TO MEASURE

TEMPERATURE OF INNER SURFACE
FIGURE 21
2. Temperature readings shall be taken as outlined above. 3. Ambient conditions during testing shall be maintained at
The load shall not be applied until three consecutive 24°C ±3°C (75°F ±10°F) with minimal air flow across the
temperature readings from the thermal barrier specimen.
thermocouple agree within ±1°C (±2°F) of the desired
temperature setting. The period of temperature 7.2.4 Report
stabilization shall not be less than 5 minutes nor shall the
time between consecutive readings be less than 1 minute. 7.2.4.1 A report of test results should generally be in
Failure to allow the test specimen to stabilize at the accordance with ASTM Standard Practice E575.
equilibrium temperature as measured by the thermal barrier
thermocouple will result in non-reproducible results. 7.2.4.2 As a minimum, the information included in
attachment A shall be included in the report format.
(Reference Section 8.2).

7.3 Shear, Tension and Eccentric Load Tests
TEST
FIXTURE
LOAD 'P'
LOAD 'P'
APPLICATION
POINT
CRITICAL
DEBRIDGED
THERMAL
BARRIER
SHEAR
TEST
FIGURE 22
7.3.1 Scope 7.3.2 Sample

This method describes procedures for determining the A sufficient number of pieces of test extrusions shall be
shear, tensile and eccentric loading strengths of thermal selected in such a manner as to be representative of the
barrier materials. shipment. The number of specimens required for the
purpose of this test shall be cut from the pieces selected
above and care shall be taken to select sections that are free
from obvious defects. Any samples with noticeable
imperfections (cracks, bubbles, etc.) shall be discarded.

LOAD 'P'
TENSILE
TEST TEST
FIXTURE
LOAD 'P'
TEST
FIXTURE
FIGURE 23

CENTERLINE OF
THERMAL BARRIER
TEST d
FIXTURE
LOAD `P'
APPLICATION
POINT
CRITICAL
RECORD TEST RESULTS AS P TIMES d
TEST
FIXTURE
ECCENTRIC
LOAD TEST
FIGURE 24
7.3.3 Test Conditions centered and done in such a manner as not to cut into or
Unless otherwise specified, tests shall be conducted at 24°C otherwise notch the thermal barrier material while
±3°C (75°F ±5°F). Sections 6.5 and 6.6 provide guidance completely removing the metal bridge. Unless otherwise
to the design professional in determining the appropriate specified, the composite assemblies shall be allowed to
conditions for his/her project requirements. cure a minimum of seven days according to the supplier's
recommendations. For crimped in place thermal barrier
7.3.4 Test Specimens systems, care should be taken to properly knurl and crimp
Ten specimens each 100 mm ±1.0 mm (4.00 in ±0.04 in) in the preformed thermal barrier in place.
length shall be cut with smooth, square cut edges from
extrusions whose dimensions, shape and composition 7.3.6 Apparatus
represent the desired test extrusion. A universal testing machine capable of exerting a force of
up to 2250 N (10,000 lbs) at a crosshead speed of 5.0
7.3.5 Preparation of Specimens mm/min (0.2 in/min) shall be used.
The thermal barrier material to be tested in the extrusion
shall be poured and debridged or inserted and crimped in For gripping the shear test specimens a test fixture designed
accordance with the supplier's recommendations. For for offset loading shall be required. The test fixture shall
polyurethane thermal barrier systems, special care shall be prevent rotation of the specimen under load and shall
taken to ensure that the polyurethane is mixed at the correct provide clearance for downward travel of the loaded side.
ratio, to complete uniformity and fully fills the cavity of the A bearing plate shall be placed on top of the unsupported
extrusion. In addition, debridging shall be properly side of the test specimen.

For shear testing, the test fixture shown in Section 7.3, controlling test temperature. All three thermocouple
Figure 22 or its equivalent shall be used. It should be noted readings shall be recorded in the test report.
that this test fixture is the same one used in the eccentric
loading test except that the top plate has been rotated 180° Temperature readings shall be taken as outlined above.
to provide clearance for offset loading. For gripping the The load shall not be applied until three consecutive
tensile test specimens a slotted, self aligning test fixture temperature readings from the thermal barrier
shall be required. For tensile testing, the test fixture shown thermocouple agree within ±1°C (±2°F) of the desired
in Section 7.3, Figure 23 or its equivalent shall be used. temperature setting. The period of temperature
Figures 22, 23 and 24 show the test specimens mounted in stabilization shall not be less than 5 minutes nor shall the
the shear, tension and torsion fixtures respectively. In all time between consecutive readings be less than 1 minute.
cases, the applied loads shall be distributed as uniformly as Failure to allow the test specimen to stabilize at the
possible along the unsupported section so as not to distort equilibrium temperature as measured by the thermal barrier
or bend the aluminum. In some cases, the thermal barrier thermocouple will result in non-reproducible results.
will be stronger than the aluminum and distortion of the
aluminum is unavoidable. 7.3.8 Report
7.3.7 Procedure 7.3.8.1 A report of test results should generally be in

accordance with ASTM Standard Practice E575.
7.3.7.1 Tests at Temperatures Below Room Temperature
The test specimen and test fixture shall be placed in a 7.3.8.2 As a minimum, the information included in
suitably equipped environmental test chamber mounted on attachment B shall be included in the report format.
the universal testing machine. A thermocouple shall be (Reference Section 8.2).
inserted into a hole 1.5 mm (0.062 in) in diameter and 5 7.4 System Performance
mm (0.2 in) deep drilled into the midpoint of the thermal Composite thermal barrier systems must perform not only
barrier compound along its centerline at a point 75 mm (3 thermally but also equally well as a structural component of
in) from the end of the specimen. When the temperature the total building system. For structural performance, refer
indicated by the thermocouple has stabilized at the desired to AAMA 505. In addition, they must perform
value, the load shall be applied at a strain rate of 5 mm/min satisfactorily in resisting air and water infiltration. The
(0.2 in/min) until failure occurs. For torsional testing, the system performance limits should be set by the architect or
face of the compression rod shall be approximately engineer responsible for the project. AAMA has developed
centered on the fin of the extrusion closest to the thermal a series of minimum performance requirements and test
barrier material. Record test results as the moment methods to aid the design professional. A discussion of
developed from the applied load times the distance of the these tests and standards is given in the following
applied load to the centerline of the thermal barrier. For paragraphs. More complete information is available in the
shear and tensile testing, record the peak load and the mode documents which are listed in Section 9.0 References.
of failure (whether cohesive within the thermal barrier
material or whether the thermal barrier material pulled free 7.4.1 Structural
from the extrusion cavity projections) or, as in the case of (AAMA Curtain Wall Guide Specifications, par 1.07.B)
shear testing, slipped parallel to the direction of travel. This test is performed in accordance with ASTM E330.
Design limits for deflection at design load are held to 1/175
7.3.7.2 Tests at Room Temperature of the clear span for curtain wall, storefront and HC and
The same procedure as in Section 7.3.7.1 shall be used AW windows. At a test pressure of 1.5 times the design
except that the environmental test chamber and load, permanent deformation is limited to 0.2% of the clear
thermocouple temperature probes are not required. Room span for main curtain wall, storefront, entrance framing and
or ambient conditions shall be maintained at 24°C ±3°C AW windows and doors, 0.3% for HC and C windows and
(75°F ±5°F). doors and 0.4% for R and LC windows and doors. Glass
7.3.7.3 Tests at Temperatures Above Room Temperature breakage, permanent damage to fasteners, anchors,
The same procedure as in Section 7.3.7.1 shall be used hardware or actuating mechanisms is not permitted.
except that the environmental test chamber shall be 7.4.2 Water
replaced by an electrical heat tape. The heat tape shall be (AAMA Curtain Wall Guide Specifications, par 1.07.D)
applied to the exterior face of the aluminum extrusion. This test is performed in accordance with ASTM E331.
Thermocouples shall be located under the heat tape, The appearance of uncontrolled water other than
imbedded in the center of the thermal barrier material and condensation on the indoor face of the wall is not allowed.
on the surface of the interior face of the aluminum Static test pressure is usually 20% of the architect specified
extrusion. The thermocouple under the heat tape shall be in design pressure for curtain wall, storefront, entrance
direct contact with the metal surface but shall be shielded framing and AW windows and 15% of the design pressure
from direct contact with the heat tape by means of an for R, LC, C and HC window, door and panel members.
insulating shim. (See Figure 21) The temperature For curtain walls, a dynamic test for water penetration is
measured by the exterior face thermocouple shall be the

also frequently run at the same test pressures. Penetration with AAMA 507. In general it is up to the architect to
of a small amount of water is considered permissible, determine how the job conditions relate to test conditions,
provided it is contained and drained back outside (or particularly test size versus installed framing size.
"controlled"), with no damage to the wall or adjacent
structures. 7.5 Structural Design Method for Composite
Aluminum/Elastomer Beams
7.4.3 Air
(AAMA Curtain Wall Guide Specifications, par 1.07.C) 7.5.1 Overview of Sandwich Beams
This test is performed in accordance with ASTM E283. Why do we need to treat thermal barrier beams differently
The test pressure is specified by the architect with 1.57 psf than ordinary beams? This discussion addresses this
usually being the minimum test pressure. Air infiltration is question.
limited to 0.3 L/s•m2 (0.06 cfm/ft2) per square foot of
The key structural difference between an all-aluminum
projected wall area for fixed storefront and curtain wall
beam and a composite, thermal barrier beam is core
glazing. 101/I.S. 2/NAFS-02 provides air leakage limits
(thermal barrier) shear deformation. Most of the behavior
for all other fenestration types. Air infiltration is measured
of an all-aluminum beam can be modeled using the
after a tare reading for air leakage of other building
components or the test chamber is deducted. traditional Bernoulli-Euler equation (E I y′′ = M) for flexure,
while ignoring shear strain. However, introduction of a
7.4.4 Thermal relatively soft material for a part of the web (thermal barrier
(AAMA Curtain Wall Guide Specifications, par 1.07.E) or core) results in a more complex behavior of the beam.
Thermal performance standards are especially important Initially plane (flat) cross-sections of the beam do not
for thermally improved framing systems. Thermally remain so after loading, due to significant effects from
broken systems offer a considerable reduction in the shear deformation of the core. Core shear strain entails
formation of harmful condensation on the interior of the rectangular blocks of the core, with length parallel to the
glazing. A considerable reduction in heat flow or thermal beam’s span, distorting into parallelograms.
transmittance is also a benefit provided by thermally
broken systems. Both of these performance improvements Beam deflection and aluminum stress both increase, due to
may be relatively measured by AAMA 1503. the presence of a core which is “soft” compared to
aluminum. On the other hand, the value of longitudinal
7.4.4.1 Condensation Resistance Factor (AAMA 1503) shear flow (shear stress times core width) is less with a core
The Condensation Resistance Factor (CRF) is a rating than for an otherwise similar, all-aluminum beam.
number, obtained under standard test conditions, which
allows comparison within reasonable accuracy, of the There is another way to think of thermal barrier beam
condensation performance of windows, doors or glazed behavior, besides the concept of altering an all-aluminum
wall sections. CRF ratings are derived at standard test beam so that it becomes more flexible and more highly
conditions of -18°C (0°F) on the cold side of the specimen, stressed. One can consider the idea of joining two separate
21°C (70°F) on the warm side and a uniform air flow pieces of aluminum to create a beam which is stiffer and
against the cold side of the specimen of 7m/s (15 MPH). stronger than the un-joined pieces. As an example, two
Temperatures on the surface of the specimen are used to identical aluminum bars are placed, one on top of the other,
compute a CRF rating. so as to span between supports. (See Figure 25) A certain
midspan load will cause the beam to sag 25 mm (1 in) (Case
Since CRF is determined for a pre-specified configuration ‘a’). In this set-up, the two bars are free to slide along each
under controlled laboratory conditions, caution must be other so that the top of the lower bar is in compression and
exercised in using CRF to predict field performance against the bottom of the upper bar is in tension. Now assume (Case
the formation of condensation. ‘b’) that the two bars are “glued” together so that any strains
in the contacting bar surfaces are forced to be identical. The
7.4.4.2 U Factor (AAMA 1503 and AAMA 507) same load and span will now produce only 6 mm (1/4 in)
The Thermal Transmittance (U factor) is the time rate of deflection and half as much bending stress. These
heat flow, per unit area, under steady state conditions, improvements come at a cost however, since the “glue”
through a body for a unit temperature difference of air on must resist a longitudinal shear flow which is equal to the
either side of the body. The AAMA 1503 test method used maximum shear flow that exists within each bar in Case ‘a’.
to determine a U factor is a modification of ASTM C236.
The test chamber conditions are the same as for the CRF The behavior of a thermal barrier beam is, in a sense,
procedure given above. The calculation of U Factor is a between Case ‘a’ and Case ‘b’. If the glue acquires a finite
function of inside and outside surface coefficients as thickness and exhibits significant shear deformation, then
determined by measured specimen surface temperatures one has a model of a composite thermal barrier beam. The
and affected by air flow. There are many factors that can core’s shear stiffness engages the axial stiffness of each face.
impact the actual U Factor of a glazing installation such as In addition, the core forces both faces to deflect the same
glass type and glass to frame ratios. These variables are amount, and so the individual bending stiffness of each face
taken into account for U-Factors determined in accordance also assists in resisting the load.

A
b
Layer 1
t
L t
Layer 2
Free to Slip Typical Cross Section A-A
Case (a)
t
t
P
d/4
b
Layer 1
t
L t
Layer 2
No Slip at Interface Typical Cross Section A-A
Case (b)
FIGURE 25

7.5.2 Introduction to Method 7.5.3 Variables
Section 7.5 describes a design method for predicting the This section presents the variables needed as input for the
stiffness (effective moment of “inertia” [second area design method. Refer to Figures 26 and 27 for illustration
moment]), effective section modulus, and core shear for a of most of these quantities.
simple span beam with a non-homogeneous cross-section,
subject to midspan concentrated, uniform, triangular or A Shear area of aluminum, which equals total
trapezoidal load. All load types are symmetrical about the (average) web thickness (tw) times net web
midspan of the beam. The model is a “sandwich” beam height (h - g). See definitions for other
consisting of relatively stiff faces (e.g., aluminum) variables.
continuously joined to a much softer core material (e.g., an
elastomer such as polyurethane, or a material such as glass- Ac Total cross section area of core (elastomer).
fiber reinforced nylon [polyamide]). The faces (also a Length of linearly increasing part of
termed facing sections) may have significant bending trapezoidal load.
stiffness in addition to axial stiffness. The core (thermal
barrier) is assumed to resist only shear. a1, a2 Areas of faces 1 and 2.
b Average width of core (elastomer); b = Ac/Dc
The method has been compared with over 60 tests (using
concentrated load on beams with P & DB polyurethane b′ Clear opening between interlocks; usually the
cores) and found to predict trends in behavior and to least width of the core.
produce reasonably consistent numerical results.
c11, c22, D Distances between centroidal axis and air side
Refer to references [1], [2], [3], [6] and [8] for details of the surface of each face, and between axes,
derivation of the final equations. respectively.
Dc Cavity depth (maximum).
Note that Young's modulus (E) of the “exterior” and
“interior” metal components (facing sections, or simply E Young's modulus of aluminum faces; 68,950
faces) is assumed to be “large” compared to that of the core MPa (E = 107 psi = 104 ksi).
(elastomer). Thus only a very small error, on the safe side,
Ec Young's modulus of core (elastomer).
is introduced in the analysis by considering the metal
pieces to alone carry flexural (bending) stresses. For g Gap (clearance) between faces.
example, if the E of the elastomer is 2,068 MPa (300,000
psi), it is only 3% of the aluminum modulus of 68,950 MPa Gc Shear modulus of core (elastomer). [See
(10,000,000 psi). Thus, a 12 mm (1/2 in) wide elastomer discussion at end of input list].
element is only 0.39 mm (0.015 in) wide in terms of an h Overall depth of extrusion; h = c11 + D + c22
equivalent piece of aluminum. In most cases this is small
compared to other section dimensions. This small h1 , h2 Dimensions from extrusion's center of gravity
difference could be addressed by including the core to air side of faces 1 and 2
moment of “inertia” (times the elastomer-to-aluminum
Io1, Io2 Moments of “inertia” (second area moments)
modular ratio), but this has not been included in the
of faces 1 and 2.
method.
k Dimensionless ratio (a/L) for trapezoidal
7.5.2.1 Load Due to Temperature Difference load.
A temperature difference between faces (and/or within a
face) will cause bow (deflection), bending stresses and core L Span, center-to-center of supports.
shear stresses in thermal barrier beams that are composite. P Concentrated load (force).
There are no closed-form equations in this document to
predict this behavior. Finite element analysis (FEA) may, tw Thickness of strong axis web, or the total
however, be used. With varying accuracy, two or three- webs, of the aluminum extrusion. More
dimensional (2-D or 3-D) general purpose, or 2-D special generally, tw = Aw/(h-g) where Aw is the sum
purpose FEA, software is capable of predicting a response of individual web thicknesses (in each face)
to a temperature gradient. Refer to references [4] and [6] times height of the pertinent facing section.
for information on special purpose FEA. Combined
w Uniform load intensity (force/length).
loading, consisting of wind and a given set of four
temperatures (air side and core side of each face), can also wo Maximum intensity of triangular and
be modeled with FEA. trapezoidal load (force/length).
Consistent units are to be used throughout all equations.

7.5.3.1 Discussion on Shear Modulus Gc In order to address possible reduction in effective moment
Even if a test value of shear modulus for the core material of “inertia” (I'e) at temperatures higher than room
alone is known, for core (thermal barrier) material temperature (e.g., warmest field conditions), it is
specimens, it is necessary to obtain a design value of Gc by recommended that I'e for a test beam at the appropriate
comparing test beam results to predictions of effective elevated temperatures be measured. If the I'e is
moment of “inertia” (I'e) using various Gc estimates. Refer significantly lower than at room temperature, then the same
to Section 7.2 for flexural test. This procedure results in a iterative calculation process may be used to find the
value of “effective” shear modulus, at least for a given appropriate (reduced) “average” effective Gc for that
elastomer, cavity, and profiles with the same general shape. temperature distribution in the elastomer. The value of Gc
One way of aiding this determination of Gc is to plot the will be an average because the actual Gc may, in general,
“predicted effective I” versus “span L” for several values of vary with the core temperature. Core temperature varies
Gc. By then plotting the test effective I at each of at least 2 through the depth of the core if the temperatures of the
spans, on the graph containing the predicted value, an exterior and interior faces differ. Note that the use of more
approximate (design) value of Gc can be determined. than one value of span length to get a best estimate of Gc is
recommended. If only one span length is used, and it
Having determined an effective shear modulus, this results in a “large” span-to-moment of inertia ratio, the
modulus value may be used to design for other spans with change in I'e with various Gc values may be relatively
that shape and with “similar” shapes. Here “similar” refers small.
especially to composite beams with the same cavity, core
material and method of resisting longitudinal shear. For the types of beams considered in this document, the
Deflection due to uniform, triangular or trapezoidal load existing test and analytical data [3] have shown that
may then also be calculated for various spans and “similar” unloaded overhangs do not significantly affect the behavior
shapes, using the Gc value from the concentrated load tests. of simple span beams (with midspan concentrated load) for
span/depth ratios of at least 20 and a shear modulus of at
The core material is assumed to be linearly elastic for the least 552 Mpa (80 ksi.) Shear modulus values less than
range of strain encountered in the core. As a starting point, 552 Mpa (80 ksi) and/or span-to-depth ratios less than
(for urethanes), Gc may be estimated to be between 0.33 Ec about 20, may result in significant differences in stiffness
and 0.4 Ec, for constant temperature condition. Note that of “overhang” versus “no overhang” beams. For such
theoretically the value for Gc is at least equal to Ec/3 and at cases, other analytical methods (e.g. finite element analysis
most equal to Ec/2. As the elastomer Young's (tension) using available software) should be used. Refer to [3], [4]
modulus Ec increases, the shear modulus is usually and [6]. “Overhang” refers to an extension, past the
expected to also increase. As shear modulus increases, the support, which is more than half the beam depth in length.
effective I of the beam would normally become less
sensitive to variations in the value of elastomer shear
modulus Gc.

1 a , I
1 o1
c 11
Centroidal
Axis 1
g D
C
D
b h
t
w
Centroidal
Axis 2
c 22
2 a , I
2 o2
FIGURE 26

P
L
L/2
wo
L/2
L
Triangular
Concentrated
L
a=kL a
wo
wo
Uniform Trapezoidal
FIGURE 27 - SYMMETRICAL LOADINGS

7.5.4 Parameters, Basic Equations and Integration Constants
a1a 2 D 2
Ic = for the case where both faces are same material (same E). (1)
a1 + a 2
Io = Io1 + Io2 which is the lower bound on stiffness I′e, assuming no composite action (i.e. slip is free (2)
to occur all along the core/aluminum interfaces).
I = Ic + Io which is the upper bound for values of I'e. This value would only be realized exactly, for (3)
I′e, if no shear deformation occurred in the core or faces.
Ic/I Ratio which indicates how much of the flexural stiffness is due to area and separation of (4)
faces, rather than to the individual I values (Io1 and Io2) of faces.
I b D2 Gc (5)
Gp = Parameter which includes geometric and core material properties.
Ic Dc
Gp (6)
c= for same E for both faces. [Note that most prior documents use Cy in lieu of c.]
E Io
The governing differential equation relating the deflected shape (y) to the beam’s bending moment (M) and shear (V) is:
−cM V′ (7)
y′ ′ ′ ′ − cy′ ′ = +
EI EIo
In this equation, the prime (') denotes differentiation with respect to x. See equation 24 in reference [2]. This fourth order
equation requires the determination of four independent constants of integration that depend on the type of loading and
boundary conditions. Related constants have been determined for a simply supported beam (without overhangs) for four
types of symmetrical loading: midspan concentrated load, uniform, triangular and trapezoidal. (See Figure 27) The
constants are combined with other terms in the final equation for the deflected shape.
F2 (8)
y = D5x5 + D4x4 + D3x3 + D2x2 + D1x + D0 + F1ep +
ep
Equivalently:
(8.a)
5 F2
y = Σ D n x n + F1e p +
n =o ep
This equation reaches a maximum at x = L/2. Note that p = x c . The expressions for the constants D0 to D5 are given in
Tables 3and 4for each of the four load types. The constants D0 to D5 for trapezoidal load apply to the region a ≤ x ≤ L – a.
For trapezoidal load in the linearly increasing load region (0 ≤ x ≤ a), the equation for deflection y is:
5 (8.b)
y = Σ E n x n + G1e p + G 2 / e p
n =0

Loading
Constant
Midspan Concentrated Uniform
w E I o Ic
D0 0 2
(G )p I
−P Ic PL2 − ( wL ) I c wL3
D1 − −
2 G p I 16 E I 2 Gp I 24 E I
w Ic
D2 0
2 Gp I
P wL
D3
12 E I 12 E I
−w
D4 0
24 EI
D5 0 0
TABLE 3 – Constants D0 → D5

Loading
Constant
Triangular (Sym.)
D0 0
⎡ − w o L 2 w o ⎤ ⎛ Ic ⎞ 5 w o L3
D1 ⎢⎣ 4 + L c ⎥⎦ ⎜⎜ G ⎟−
I ⎟⎠ 192 E I
⎝ p
D2 0
w o Ic w L
D3 + o
3 L G p I 24 E I
D4 0
−w o
D5
60 L E I
Trapezoidal Load (a ≤ x ≤ L - a)
w o Ic w oa 2Ic w o a 4
D0 + −
cG p I 6G p I 120EI
− w o LI c w o La 2 w o L3
D1 + −
2G p I 12EI 24EI
w o Ic w o a 2
D2 −
2G p I 12EI
woL
D3
12EI
w
D4 − o
24EI
D5 0
Trapezoidal (0 ≤ x ≤ a)
E0 0
E1
( 3 2
w o Ic w o Ic ( L − a ) w o −a + 2La − L
− +
3
)
caG p I 2G p I 24EI
E2 0
w o Ic w o ( L − a )
E3 +
6aG p I 12EI
E4 0
−w o
E5
120aEI
TABLE 4 – Constants D0 → D5

The expressions for F1 and F2, and for G1 and G2, are given in Table 5. The expressions for both concentrated and uniform
load have been simplified compared to the expressions given in previous documents.
Complementary Constants*
Load Type
F1 F2
PIc
Concentrated -F1
2G p I c ( e r + e − r )
− w o Ic e − r
Uniform F1e2r
cG p I ( e r + e− r )
−2w o Ic
Triangular -F1
c G p LI ( e r + e− r )
1.5
− w o Ic ( eq − e − q ) e − r
Trapezoidal ** (a ≤ x ≤ L – a) F1e2r
2c1.5G p aI ( e r + e − r )
G1 G2
−q
Trapezoidal ** (0 ≤ x ≤ a) w o Ic e
F1 − -G1
2c1.5 G p aI
TABLE 5
*r=L c/2
** q = a c
Note that e is the base of the natural logarithms.
The expressions for F1 and F2 in Table 5 have been found to be suitable for computation with the precision normally
available on personal computers, and for the application considered in this publication.
Equations (9 to 12) for effective moment of “inertia” (second area moment), without effects of shear deformation in the faces
follow. Note that y = maximum deflection.
PL3 (9)
Concentrated Load: Ie =
48Ey
wL4 ( wL ) L3 (10)
Uniform Load: Ie = =
76.8Ey 76.8Ey
4 (11)
Triangular Load: Ie = w o L
120Ey
w o L4 ( 25 − 40k 2 + 16k 4 ) (12)

Trapezoidal Load: Ie =
1920Ey
Note that since y is a function of many variables, so is Ie. In particular, Ie is a function of L (span), Gc (core shear modulus)
and type of load (e.g., concentrated, uniform, triangular or trapezoidal).

7.5.5 Correction for Shear Deformation in Aluminum Faces
The preceding expressions for an effective I can be made more accurate by accounting for shear deformation of the “web(s)” of
the metal components (facing sections). The following procedure is semi-empirical and has been found to significantly improve
predicted values, particularly at shorter spans, as compared to test values. Note that the equations for concentrated and uniform I′e
are slightly different than given in prior documents. The current expressions are improvements [8] which result in only small
changes (increases for the example problem).
Assume maximum deflection d (due to the four load types considered) of “solid aluminum” beams can be represented by:
P* L3 ⎛ 1 ⎞ P* L ⎛ F ⎞ (13)
d= ⎜ ⎟+ ⎜ ⎟
B ⎝ EI e ⎠ S ⎝ AG ⎠
Here the first term accounts for bending and the second term is for shear effects on the web(s). See Table 6 for values of B, S and
P* for the four load types.
Load Type B S P*
Concentrated 48 4 P = applied load
Uniform 76.8 8 w L = W = total
Triangular 120 12 wo L
1920 24
Trapezoidal (k = a/L) 2 2 wo L
( 5 − 4k ) 3 − 4k 2
TABLE 6
Note that uniform and triangular loads are limiting cases of trapezoidal load (k = 0 and k = 0.5, respectively).
G is the aluminum shear modulus = 0.375 E, and A is the sum of the areas of the “web” elements. Let I'e include shear
deformation effects on the aluminum web(s), so that:
P*L3
d= (14)
BEI′e
If F (form factor) is assumed equal to 1, which is approximately correct for “I” beams and appropriate values of B and S are used
for each type of loading, then the following expressions result for an all aluminum beam:
Ie (15)
Concentrated: I′e =
1 + ⎡⎣32 ( Ie ) / ( L2 A ) ⎤⎦
Uniform:
Ie L2 A Ie
I′e = = (16)
L A + 25.6Ie 1 + ⎡ 25.6 ( Ie ) / ( L2 A ) ⎤
2
⎣ ⎦
Triangular: Ie
I′e = (17)
1 + ⎣( 26 3 ) ( Ie ) / ( L2 A )⎤⎦
⎡ 2
Trapezoidal: Ie
I′e =
⎡ ⎛ 4k 2 ⎞ ⎤
⎢ 25.6 ( I )
e ⎜1 − ⎟ ⎥
⎢1 + ⎝ 3 ⎠ ⎥ (18)
⎢ (1 − 1.6k 2 + 0.64k 4 ) L2 A ⎥
⎢ ⎥
⎢⎣ ⎥⎦
Note that for very large values of L, the value of I'e is essentially Ie. In the case of small span/depth ratios (e.g., less than 10 to 1),
even this refinement of the basic approach will not account for all aspects of the structural behavior. In these cases equation (15)
has been found to predict too large a value of I'e compared to test. If attempts are being made to optimally design a short span
with a ratio less than 10 to 1, a test should be conducted.

7.5.6 Bending Stress Equations
Stress in face 1 (at distance c11 from centroidal axis 1) is:

− ( M − EI o y′ ′ ) (19)
f11 = − Ec11 y′ ′
a1D
and in face 2 (at distance c22 from centroidal axis 2) is:

M − EI o y′ ′ (20)
f 22 = + Ec22 y′ ′
a 2D
Refer to Table 7 for the expression for maximum moment for the appropriate load type. If the stress at a location other than
midspan is desired, use the more general expression in the next column.
Load Type max. M M * *Domain

Concentrated PL/4 Px/2 0 ≤ x ≤ 0.5 L
Uniform wL2/8 wx(L – x)/2 0 ≤ x ≤ 0.5 L
⎛ L x2 ⎞
Triangular woL2/12 wox ⎜ − ⎟ 0 ≤ x ≤ 0.5 L
⎝ 4 3L ⎠
⎛ 4 ⎞ wo(-a2 + 3Lx – 3x2)/6 a ≤ x ≤ 0.5 L
Trapezoidal w o L2 ⎜1 − k 2 ⎟ / 8 2
⎝ 3 ⎠ wox(3a [L – a] – x )/(6a) 0≤x≤a
TABLE 7
y′ ′ = d2y/dx2 = 20 D5 x3 + 12 D4 x2 + 6 D3 x + 2 D2 + c [F1 ep + F2/ ep] (21)
Note that p = x c
In equation (21) for y′ ′ , substitute x = L/2 and the expressions for D5 to D2, and F1 and F2, for the particular load case. Next
substitute the resulting value for y' ' in equations (19) and (20) for f11 and f22, to obtain maximum compressive and tensile stresses.
Note that no web crippling criteria have been developed for regions subject to concentrated load.
Similar to the approach used for stiffness, an “effective section modulus” (Se) may be calculated for each face for a given load
type, span and core shear modulus, for a particular section. One value (Se1) will be for face 1 and another (Se2) for face 2.
Se1 = M / f11 (22)
Se2 = M / f22 (23)
7.5.7 Shear Stress Equations
An approximate expression for shear resisted by the core is:

(24)
Vc = V - E Io y' ' '
See Table 8 for the expression for maximum shear, which occurs at the ends (x = 0 and x = L), for the desired load type. Shear at
other locations is given in the next column.

Load Type max. V V * *Domain
P P
Concentrated 0 ≤ x ≤ 0.5L
2 2
⎛ L ⎞
Uniform wL/2 w⎜ − x⎟ 0 ≤ x ≤ 0.5L
⎝2 ⎠
woL wox2
Triangular woL/4 − 0 ≤ x ≤ 0.5L
4 L
-- wo (L – 2x)/2 a ≤ x ≤ 0.5L
Trapezoidal
wo L(1 - k)/2 wo (La – a2 – x2)/(2a) 0≤x≤a
TABLE 8
For non-trapezoidal loads (0 ≤ x ≤ L) and for trapezoidal (a ≤ x ≤ L –a): (25)

y' ' ' = d3y/dx3 = 60 D5 x2 + 24 D4 x + 6 D3 + c1.5 [F1ep – F2/ep]
As before, p = x c . Maximum V for all four load types considered occurs at x = 0, and at x = L. Thus, at x = 0, for all
load types except trapezoidal:
y' ' ' = 6D3 + c1.5(F1 – F2) (25.a)
For trapezoidal load (for 0 ≤ x ≤ a):
y' ' ' = 60 E5 x2 + 6 E3 + c1.5 [G1ep – G2 / ep] (26)
For trapezoidal load at x = 0:
y′ ′ ′ = 6E3 + c1.5 [G1 – G2] (26.a)
The fraction of total shear carried by the core is:
R= c
V
V (27)
This dimensionless ratio R is independent of load magnitude, but is a function of load type, span and core
shear modulus, for a given beam section.
The shear flow (force per unit length) is approximated by:
qc = Vc = RV (28)
D D
where D is the distance between centroidal axes of the two faces. This shear flow value may be compared to an allowable value
derived from longitudinal shear tests (see Section 7.3) for the given cavity, elastomer, and method (adhesion and/or mechanical
indentations) of resisting slip longitudinally.
Note that an upper bound value of qc may be calculated by the formula:

VQ Va n ( h n − c nn )
qc = = (28.a)
I I
This formula for shear flow is less accurate, but conservative. It results in almost the same values, as equation (28), for high
values of core shear modulus and span. In cases where the composite centroidal axis passes through the clear space (gap)
between faces, n equals 1 for all subscripts (or it may be set to 2 for all subscripts). In other cases, n corresponds to the face
which does not contain the composite centroidal axis. Refer to the figure in the example for an illustration of h1 and h2.
The approximate maximum core shear stress, at maximum Vc, is:

Vc
f vc = (29)
b′D
where b' equals the minimum core width (which normally occurs between the aluminum interlocks).

7.5.8 Example Substituting in equations (1) to (4) for
To illustrate use of the equations, consider the following values (based on the various parameters:
measurements, not the nominal die drawing dimensions) for an AAMA test Ic = 0.6689 in4
extrusion. Note that CAD software may be used to calculate section Io = 0.6393 in4
properties of faces 1 and 2. This example is given in IP units only. I = 1.3082 in4
Ic / I = 0.5113
In this example Gc = 80 ksi at room temperature, and effective Gc = 20 ksi at
an elevated temperature. This effective Gc was determined at a mid-cavity Note that I = Ic + Io is the upper bound
temperature of about 105°F with “exterior” aluminum maximum temperature value of moment of “inertia” (second
about 160°F, “interior” aluminum ≥ 80°F, and room air about 70°F. area moment) which would only be
attained if there were no shear
deformations of the core or faces and no
a , I slip occurred. Io = Io1 + Io2 is the lower
1 o1 1
bound, which would apply if the faces
were free to slip along the core.
c Effective Moment of Inertia:
11
Calculate deflection y from Eq. (8), and
Ie from Eq. (9) and (10). First use
expressions from Table 3 for D5 to D0 for
concentrated and uniform load, and
g DC expressions from Table 5 for F1 and F2.
Now calculate y (at x = L/2) and Ie, at
h
1 this maximum value of y. Next compute
D I'e, using Eq. (15) and (16) respectively.
Values are presented in Table 9 for
several spans.
h
Effective Section Modulus:
Refer to Eq. (19) to (23), and appropriate
expressions for maximum moment in
h Table 7, to calculate values of effective
2 tw c 22 section moduli Se1 and Se2. Values are
given in Table 10.
For comparison note that if the core were

replaced by a thin aluminum bridge, the
section modulus values (using distances
h1 and h2 to the centroidal axis of the
a , I entire section) would be approximately:
2 2 o2
S1
FIGURE 28 = 1.3082 in4/1.5845" = I/h1
= 0.8256 in3 TOP ("exterior", face 1)
a1 = 0.2377 in2 I01 = 0.00188 in4 c11 = 0.1059"
a2 = 0.8222 in2 I02 = 0.6374 in4 c22 = 1.2763" S2
D = 1.9046" = 1.3082 in4/1.7035" = I/h2
Dc = 0.807" which is the maximum depth of the polyurethane. = 0.7679 in3 BOTTOM ("interior", face 2)
tw = 0.107"
A = 0.3121 in2 = tw (h-g) = 0.107" (3.287" - 0.370") = web area In other words the above values are the
Ac = 0.355 in2 = 0.56" (0.37) + 2(0.062") (0.25) + 0.156" (0.375") = core area usual section modulus values from
g = 0.370" clear (gap) ordinary beam theory. These two values
b = 0.440" which is the “average width” = Ac/Dc = 0.355in2/0.807" may be compared to the effective section
E = 10,000,000 psi = 10,000 ksi = Young's modulus of aluminum moduli (that include the effect of the
Gc = (See tables for values considered polyurethane core, span and load type) in
L = (See table) = span Table 10.
P = 100 pounds; concentrated load at midspan
w = 100 pounds divided by span L; uniform load

Elastomer Concentrated Load Uniform Load
Span L (in) Shear Modulus Gc (ksi) Predicted Effec I Predicted
I′e/Ie I′e/Ie
I′e (in4) by test (in4) I′e (in4)
48 20 0.9566 0.9765 1.02 0.9647 0.9924
80 0.9494 1.1381 1.08 0.9587 1.1574
72 20 0.9779 1.1128 1.10 0.9822 1.1266

80 0.9758 1.2231 1.23 0.9805 1.2348
96 20 0.9868 1.1830 -- 0.9893 1.1943

80 0.9860 1.2578 -- 0.9887 1.2654
TABLE 9 - Effective Moment of Inertia
Concentrated Load Uniform Load

Shear Modulus
Span L (in) Se1 Se2 Se1 Se2
Gc (ksi)
(TOP) (in3) (BOTTOM) (in3) (TOP) (in3) (BOTTOM) (in3)
48 20 1.221 0.640 1.049 0.679
80 0.988 0.698 0.880 0.740
72 20 1.056 0.677 0.924 0.721

80 0.927 0.720 0.849 0.755
96 20 0.988 0.698 0.880 0.740

80 0.900 0.731 0.839 0.761
TABLE 10 - Effective Section Moduli (for midspan stress)
Concentrated Uniform
Shear Modulus P = 100 lbs W = 100 lbs = wL
Span L (in)
Gc (ksi) R = Vc/V Vc/D = qc R = Vc/V Vc/D = qc
Vc (lbs) Vc (lbs)
* (lbs/in) (lbs/in)
48 20 0.439 21.9 11.5 0.320 16.0 8.4
80 0.506 25.3 13.3 0.414 20.7 10.9
72 20 0.492 24.6 12.9 0.382 19.1 10.0

80 0.511 25.5 13.4 0.447 22.3 11.7
96 20 0.506 25.3 13.3 0.414 20.7 10.9

80 0.511 25.5 13.4 0.463 23.1 12.2
TABLE 11 - Core Shear (Maximum; refer to Section 7.5.7)
*Note that VQ/I = 13.43 lbs/in, per equation (28.a), for P = 100 lbs.

I' e (Predicted using measured dimensions)
Concentrated Load (Hartsock); Dc = 0.811", b=0.440"
4
3
I = I + I = 1.3082 in4
2 o c
1
Core 80
1
Shear
9 Modulus
Gc (ksi) 20
8
6
I = I + I = 0.6393 in4
o o1 o2
5 AAMA
test shape
4 (modified)
Roomtemperature elastomer
3
40.5 °C(105 °F) average elastomer temperature
2 {71.1 °C (160 °F) maximumand 26.7 °C(80 °F) minimum
aluminumtemperatures}
1
2' 4' 6' 8'
0
0 20 40 60 80 100
SPAN (inches)
FIGURE 29
TIR-A8-04 includes a software program for the structural design method set forth in Section 7.5 for composite
aluminum/elastomer beams. This makes the method practical for quick, simple and suitably accurate evaluation of composite
properties for many shapes and sizes of extrusions.
The authors of the revised version of Section 7.5 are:

James C. LaBelle, P.E., Doc.E.; [Computerized Structural Design, S.C.]
and
Mal Davies, HND (Engineering], BA (Honors 1st class: Math/ Physics)

7.6 GLOSSARY OF TERMS CURING - The completion of the chemical reaction after
the initial reaction and until maximum physical properties
AMBIENT TEMPERATURE/CONDITIONS - The are achieved. This process typically continues after
temperature or conditions (humidity, air velocity, light debridging.
exposure, etc.) which surround or encompass the area of
concern, i.e., a test specimen, framing member, etc. CYCLIC BENDING - The repeated application and
removal of a bending load to a framing member so as to
ANGULAR DISTORTION - The rotation of the exterior investigate fatigue life, composite interaction, possible
face of the framing member from its nominal position. changes in physical properties, etc.
Normally this is caused by thermal stresses during pouring
and curing, improper crimping of thermal strut, improper DEBRIDGING - The process whereby the aluminum
handling or uneven glazing pressures. bridge connecting the exterior and interior portions of the
extruded thermal barrier cavity in a poured and debridged
BRIDGE - The portion of the extruded framing member in design is removed either by milling or sawing.
a poured and debridged design that connects the exterior
face with the interior structural portion of the frame. This DEBRIDGING TIME - The minimum time required for
portion of the thermal barrier cavity is removed by sawing the mixed thermal barrier material to develop sufficient
or milling after pouring and curing of the thermal barrier hardness to allow debridging.
material.
DEFLECTION RESISTANCE - The ability of the
CATALYST - A substance, usually present in small thermal barrier material to resist distortion due to wind
amounts relative to the polyol and isocyanate reactants, that loading, gasket pressure, fabrication or handling which
modifies, especially increases, the rate of the chemical would exceed the deflection limits specified for the
reaction without being consumed in the process. product.
CAVITY - The hollow, channel or void provided in the DENSITY - The mass per unit volume of a material, i.e.,
extruded framing member into which the thermal barrier the mass of the thermal barrier material divided by the
material is inserted. volume of that material.
COMPOSITE SECTION - Any combination of EFFECTIVE MOMENT OF INERTIA - The moment

aluminum and one or more non-metallic materials such as of inertia (second area moment), adjusted to account for
elastomers, polyurethane, plastics, vinyl, etc. which are shear effects. Used to find the deflection of a composite
used as a thermal barrier joining the aluminum sections. beam that is loaded.
The components of this structure act together in such a
manner that their joint structural performance is greater ELASTOMERIC MATERIAL - A term often used for
than the performance of the sum of the individual rubber and polymers that have properties similar to those of
components acting separately. rubber. Thermal barrier polymers having the elastic
properties of natural rubber.
COMPRESSION STRENGTH - The maximum
compressive stress which a material is capable of ELONGATION - Increase in length expressed as a
sustaining. Compressive strength is calculated from the percentage of original length. The extension or growth of a
maximum load during a compression test and the original material in one direction usually with a shrinkage or
cross-sectional area of the specimen. reduction in one or both of the other orthographic
directions.
CONDENSATION RESISTANCE FACTOR (CRF) -
A rating number obtained under standard test conditions EXTERIOR - The portion of the framing or glazing
which allows the prediction, within reasonable accuracy, of system which is on the outside or weather side of the
the ability of a window, door or glazed wall to resist the thermal barrier.
formation of condensation on interior surfaces.
EXTRUDABILITY LIMITS - A set of guidelines
CURE TIME - The period of time that a reacting established by The Aluminum Association and the
thermosetting material is exposed to specific conditions to Aluminum Extruders Council that provides quality
reach a specified property level. The time required for a extrusions with standard tooling. Dimensional tolerances,
poured and debridged section to develop maximum gap-width ratios, extrusion factor and inscribing circle are
physical properties. examples of these limits.

FENESTRATION - The design and placement of MANUFACTURER - The fabricator of thermal framing
windows in a building or the opening(s) in a building. stock lengths into window framing systems and
components. (Many manufacturers insert the thermal
FLEXURAL MODULUS - The ratio of nominal stress to barriers into their own stock length extrusions using
corresponding strain below the proportional limit of a thermal barrier materials from a thermal barrier supplier.)
material. A constant or coefficient which expresses the
degree to which a substance is subject to bending. (The MATERIAL SAFETY DATA SHEET (MSDS) - Data
Modulus of Elasticity as determined, by calculation, from a for evaluating hazards, toxicity and proper handling of
bending test.) chemicals are furnished by thermal barrier suppliers in the
form of a MSDS.
FLUID HEAD - The amount of thermal barrier material
that is forced ahead of the filling nozzle. This material MECHANICAL LOCKING THERMAL BARRIERS –
promotes complete filling of the cavity and reduces the Thermal barrier system comprised of two separate
likelihood of entrapped air bubbles or voids in a poured aluminum extrusions crimped together by a preformed
and debridged design. thermal strut. The thermal strut reduces the heat transfer
between the two aluminum extrusions.
GEL TIME - The period of time from the initial mixing of METHYLENE CHLORIDE - Solvent formerly used for
the reactants of a plastic or rubber composition to the time cleaning and flushing thermal barrier compounds from the
when gelation occurs, as measured by a specific test. The nozzles and operating parts of the mixing and filling
time in seconds for the mixed thermal barrier material to machine. (Suspected of being an animal carcinogen.)
change from a liquid to a solid including mixing time.
MIXING RATIO - Amount of resin component with
HARDNESS - Resistance of a material to indentation or respect to the isocyanate component present in a poured
scratching. The ability of the thermal barrier material to and debridged thermal barrier material measured either by
resist compression or indentation as measured by a volume or by weight.
durometer.
NOZZLE SETTING - Adjustment to the filling machine
IMPACT STRENGTH - Resistance to fracture under to control the rate of flow of the thermal barrier material
shock force. The ability of the thermal barrier material to into the cavity and maintain the proper fluid head during
resist breaking, cracking or shattering when subjected to a filling.
sudden concentrated load. Impact loads may occur during
handling, installation or fabrication of the framing PHYSICAL INTERLOCK - The provision in the design
members. of the thermal barrier cavity that involves the incursion of
metal lugs into the cavity area. These lugs prevent the
IZOD IMPACTOR - A machine designed for the testing pulling apart of the aluminum components from the
of the impact resistance of materials such that the specimen thermal barrier material should a loss of adhesion occur.
is held as a vertical cantilever beam and is broken by a
single swing of a pendulum with the line of initial contact POLYOL - A polymer or copolymer terminated with one
at a fixed distance from the specimen clamp and from the or more hydroxyl groups (OH).
centerline of the notch and on the same face as the notch as POLYOL COMPONENT - One of the two components
described in ASTM D256. of a poured and debridged thermal barrier system.
Normally in this application, it is a fully compounded blend
INTERIOR - The portion of the framing or glazing system of polyether polyols with small amounts of catalyst and
which is on the inside or occupied side of the thermal additives present.
barrier.
POLYURETHANE - Product produced by the reaction of
ISOCYANATE - An organic compound having at least a polyfunctional isocyanate with a polyol or other reactant
one isocyan group united with an oxygen (NCO). containing two or more hydroxyl groups.
ISOCYANATE COMPONENT - One of the two POUR SPEED - The speed at which the material flows
components of a poured and debridged thermal barrier from the nozzle into the cavity and the part being filled
system. Normally in this application, it is a polymeric moves under the nozzle.
isocyanate or a blend of materials whose major component
is an isocyanate. POURED AND DEBRIDGED - Framing system thermal
barrier made by flowing a catalyzed liquid material with
KNURLING – The notching of the aluminum cavity low thermal conductivity into a one-piece channel and then
before the thermal barrier is inserted which holds the removing the base of the channel or bridge after
mechanical locking thermal barriers. solidification to form a thermally improved extrusion.

PROPYLENE CARBONATE - Solvent used for cleaning THERMAL CYCLING - The repeated heating and
and flushing thermal barrier compounds from the nozzles cooling of a specimen from a stated low temperature to a
and operating parts of the mixing and filling machine. stated high temperature and back again.
RESIN COMPONENT - A synonym for polyol THERMAL EXPANSION - An increase in the

component. dimensions of a material in direct proportion to the rise in
its temperature and conversely a dimensional shrinking as a
ROLLING - the crimping of the aluminum cavity into the result of a drop in temperature.
preformed thermal barrier.
THERMAL SHORT-CIRCUIT - The by-passing of the
ROOM TEMPERATURE - Temperature normally low conductivity of the thermal barrier material by a highly
experienced in the average workplace and defined as 24°C conductive material such as aluminum or a steel fastener.
±6°C (75°F ±10°F). If the aluminum bridge were not removed or debridged
from the cavity it would become a thermal short circuit.
SHEAR STRENGTH - The maximum shear stress that a THERMAL TRANSMITTANCE (U VALUE) - The
material is capable of sustaining. Shear strength is time rate of heat flow, per unit area, under steady state
calculated from the maximum load during a shear or conditions, through a body for a unit temperature difference
torsion test and is based on the original dimensions of the of air on the two sides of the body.
cross section of the specimen. Ability of the thermal
barrier material to resist slippage or tearing parallel to the THRESHOLD LIMIT VALUE - There are three
line of application of loading (pure or transverse shear) or categories of Threshold Limit Values.
perpendicular to the line of load application as in bending
(longitudinal shear). 1. The Threshold Limit Value - Time Weighted Average
(TLV-TWA) - The time weighted average concentration
SHRINKAGE, DRY - A uniform, end to end contraction for a normal 8-hour workday and a 40-hour workweek, to
of the thermal barrier material in the extruded cavity after which nearly all workers may be repeatedly exposed, day
the material has been fully cured. Dry shrinkage is after day, without adverse effect.
characterized by the absence of thermal barrier resin on the
cavity walls in the "shrink back" area. 2. Threshold Limit Value - Short Term Exposure Limit
(TLV-STEL) - The concentration to which workers can be
SHRINKAGE, WET - The end to end contraction of the exposed continuously for a short period of time without
freshly poured thermal barrier material as it gels or sets up suffering from 1) irritation, 2) chronic or irreversible tissue
within the extruded cavity caused by the center of the pour damage, or 3) narcosis of sufficient degree to increase the
solidifying quicker than the outer perimeter. Wet shrinkage likelihood of accidental injury, impair self-rescue or
is characterized by a thin layer of thermal barrier resin on materially reduce work efficiency, and provided that the
the cavity walls in the "shrink back" area. TLV-TWA is not exceeded. It is not a separate
independent exposure limit, rather it supplements the time-
SUPPLIER - The source of the thermal barrier material to weighted average (TWA) limit where there are recognized
the framing manufacturer. acute effects from a substance whose toxic effects are
primarily of a chronic nature.
TENSILE STRENGTH - A property of solid material that
indicates its ability to withstand a uniaxial tensile load. The 3. Threshold Limit Value - Ceiling (TLV-C) - The
ability of the thermal barrier material to resist cohesive or concentration that should not be exceeded during any part
adhesive failure during the application of a tensile load of the working exposure.
tending to pull the interior and exterior sections of extruded TORSIONAL STRENGTH - The ability of the thermal
framing apart. barrier material to resist twisting or rotation as a result of a
torsional load such as that resulting from thermal stresses,
THERMAL BARRIER (AKA THERMAL BREAK) - handling, fabrication or uneven glazing pressure.
A solid or cellular material having a low thermal
transmittance placed between materials of high thermal ULTRAVIOLET EXPOSURE - The exposure of the
transmittance for the purpose of insulating and the thermal barrier material to light in the ultraviolet range of
reduction of heat flow. the spectrum primarily from direct or reflected sunlight.
THERMAL CONDUCTIVITY - The time rate of heat VISCOSITY - Resistance of a fluid to uniformly
flow, under steady conditions, through a unit area, per unit continuous flow with out turbulence, inertia, or other
temperature gradient in the direction perpendicular to the forces. The decree to which the thermal barrier material
area. A measure of the ability of a material to transfer heat resists fluid flow under a given applied load and at a
energy from one face of a material to the opposite face, the given temperature.
opposite of thermal resistance.

8.0 ATTACHMENTS
8.1 CANADIAN RESEARCH COUNCIL TEMPERATURE STUDY

8.2 TEST REPORT FORMS
ATTACHMENT A
AAMA TEST METHOD FOR FLEXURAL LOADING OF COMPOSITE BEAM SECTIONS
MFG Name/Address: Test Date
Extrusion Identification #:
Extrusion Description:
Ambient Temperature: Exterior Surface Temperature:

Thermal Barrier Temperature: Interior Surface Temperature:
Thermal Barrier Material Description:
Sketch showing specimen orientation with respect to the point of load application and thermal barrier cavity location.
Specimen Permanent Calculated

L/175 Applied Load (P) Measured Deflection (∆)
Length (L) Deformation % of L Moment (I)
Average Calculated I mm4 (in4):

Comments:
Extrusion Die Drawing Attached for reference.
I certify that this test was conducted in accordance with AAMA Test Method For Flexural Loading of Composite Sections:
By:
Company/Position:

ATTACHMENT B
AAMA TEST METHOD FOR TENSILE, SHEAR AND ECCENTRIC LOADING

OF COMPOSITE BEAM SECTIONS
MFG Name/Address: Test Date
Extrusion Identification #:
Extrusion Description:
Ambient Temperature: Exterior Surface Temperature:

Thermal Barrier Temperature: Interior Surface Temperature:
Thermal Barrier Material Description:
Sketch showing specimen orientation with respect to the point of load application and thermal barrier cavity location.
Specimen Off Set of Load from Thermal

Applied Load (P) Measured Deflection (∆) Failure Load (P)
Length (L) Barrier Centerline (d)
Average Failure Load N (lbf):

Comments:
Extrusion Die Drawing Attached for reference.
I certify that this test was conducted in accordance with AAMA Test Method For Tensile, Shear and Eccentric Loading of
Composite Sections:
By:
Company/Position:

8.3 TEST FIXTURES
3.2 mm
3.2 mm (0.125 in) COMBINATION SHEAR
(0.125 in) 28.6 mm TYP.
TYP. (1.125 in) TORSION AND IMPACT
57.2 mm
(2.25 in)
TEST FIXTURE
SECTION A-A
22.2 mm
(0.875 in)
34.9 mm
(1.375 in)
168.3 mm
(6.625 in)
114.3 mm
(4.500 in)
54.0 mm
(2.125 in)
82.6 mm
DRILL & TAP 9.5 mm
(3.250 in)
(0.375 in) DIA. (8) 69.9 mm
15.9 mm (0.625 in) DIA. (2.750 in)
63.5 mm
9.5 mm (0.375 in) DEEP
(2.500 in)
C'SINK (8)
25.4 mm
(1.000 in)
66.7 mm 12.7 mm
(2.625 in) (0.500 in) 82.6 mm
101.6 mm (3.250 in)
(4.000 in) 57.2 mm
114.3 mm (2.250 in)
(4.500 in)
54.0 mm 25.4 mm
(2.125 in) (1.000 in)
NOTE: FIXTURE SHOWN

IN SHEAR TEST POSITION.
FOR TORSION AND IMPACT
TESTS, THE TOP PLATE
MAY BE ROTATED LEFT TO
RIGHT AND THE FIXTURE
PLACED HORIZONTALLY.
DRILL & TAP FOR

9.5 - 16 x 31.8 mm
(3 / 8 - 16 x 1 1 / 4")
SOCKET HEAD CAP
SCREW (8)
215.9 mm
(8.500 in)
190.5 mm
(7.500 in) A A
31.7 x 60.3 x 12.7 mm
(1 1 / 4" x 2 3 / 8" x 1 / 2" in)
STEEL SHIM
19.1 mm
(0.750 in)
44.5 mm
38.1 mm
(1.750 in)
(1.500 in) 25.4 mm
(1.000 in)
9.5 mm
FIGURE 30

31.8 mm DIA. TENSILE TEST
(1.250 in) FIXTURE
12.7 mm (0.500 in) DIA. DRILL THRU

HOLE AXIS MUST BE
PARALLEL TO BASE AND
MOUNTING CENTERED EXACTLY.
SHAFT
NOTE: ONE SET OF GRIPS
99.3 mm CL CONSISTS OF FOUR IDENTICAL
FIXTURE
(3.910 in) FIXTURE HALVES AND TWO
HALF
MOUNTING SHAFTS PLACED
80.3 mm TOGETHER AND WELDED
(3.160 in) AS SHOWN.
35.8 mm 16.8 mm (0.66 in)

(1.410 in)
29.5 mm
(1.160 in) 12.7 mm
(0.500 in)
18.3 mm
(0.719 in)
15.9 mm
33.3 mm (0.625 in)
SINGLE GRIP SHOWN, (1.312 in)
PAIR IS NEEDED
FOR TENSILE TESTING. 38.1 mm
(1.500 in)
76.2 mm MATERIAL IS CARBON
(3.000 in) STEEL MACHINED, DEBURED
AND ASSEMBLED AS
31.8 mm DIA. SHOWN.
(1.250 in)
12.7 mm DIA.
(0.500 in)
63.5 mm WELD SHAFT TO
(2.500 in) ASSEMBLED HALVES
60.3 mm
WELD HALVES
(2.375 in)
TOGETHER
FULL LENGTH 80.3 mm
(3.160 in)
6.4 mm (0.250 in)
29.5 mm
(1.160 in)
152.4 mm (6.000 in)
FIGURE 31

ASTM D256-03, Standard Test Methods for Determining
9.0 REFERENCES the Izod Pendulum Impact Resistance of Plastics
References to the standards listed below shall be to the ASTM D638-03, Standard Test Method for Tensile
edition indicated. Any undated reference to a code or Properties of Plastics
standard appearing in the requirements of this standard
shall be interpreted as to referring to the latest edition of ASTM D648-01, Standard Test Method for Deflection
that code or standard. Temperature of Plastics Under Flexural Load in the
Edgewise Position
ASTM D695-02a, Standard Test Method for
ANSI/AAMA/WDMA 101/I.S. 2/NAFS-02, Voluntary Compressive Properties of Rigid Plastics
Performance Specification for Windows, Skylights and
Glass Doors
ASTM D696-03, Standard Test Method for Coefficient of
Linear Thermal Expansion of Plastics Between -30°C and
AAMA 505-98, Dry Shrinkage and Composite
30°C With a Vitreous Silica Dilatometer
Performance Thermal Cycling Test Procedure
ASTM D790-03, Standard Test Methods for Flexural
AAMA 507-03, Standard Practice for Determining the
Properties of Unreinforced and Reinforced Plastics and
Thermal Performance Characteristics of Fenestration
Electrical Insulating Materials
Systems Installed in Commercial Buildings
ASTM D792-00, Standard Test Methods for Density and
AAMA 1503-98, Voluntary Test Method for Thermal
Specific Gravity (Relative Density) of Plastics by
Transmittance and Condensation Resistance of Windows,
Displacement
Doors and Glazed Wall Sections
ASTM D2240-03, Standard Test Method for Rubber
AAMA MCWM-1-89, Metal Curtain Wall Manual,
Property—Durometer Hardness
Section 1 - Guide Specifications
ASTM E283-04, Standard Test Method for Determining
AAMA QAG-1-98, Quality Assurance Processing Guide
Rate of Air Leakage Through Exterior Windows, Curtain
for Poured and Debridged Polyurethane Thermal Barriers
Walls, and Doors Under Specified Pressure Differences
Across the Specimen
AAMA SFM-1-87, Aluminum Storefront and Entrance
Manual
ASTM E330-02, Standard Test Method for Structural
Performance of Exterior Windows, Doors, Skylights and
American Society for Testing and Materials
Curtain Walls by Uniform Static Air Pressure Difference
The following ASTM documents are useful in evaluating
thermal barrier materials and thermally broken framing ASTM E331-00, Standard Test Method for Water
systems and have been referenced in the body of this TIR: Penetration of Exterior Windows, Skylights, Doors, and
Curtain Walls by Uniform Static Air Pressure Difference
ASTM C177-97, Standard Test Method for Steady-State
Heat Flux Measurements and Thermal Transmission ASTM E529-04, Standard Guide for Conducting Flexural
Properties by Means of the Guarded-Hot-Plate Apparatus Tests on Beams and Girders for Building Construction
ASTM C236-89 (1993) e1, Standard Test Method for ASTM E575-99, Standard Practice for Reporting Data
Steady-State Thermal Performance of Building from Structural Tests of Building Constructions,
Assemblies by Means of a Guarded Hot Box Elements, Connections, and Assemblies
ASTM C518-02e1, Standard Test Method for Steady-

State Thermal Transmission Properties by Means of the
Heat Flow Meter Apparatus

OTHER APPLICABLE REFERENCES
(For Section 7.5)
1. J.A. Hartsock, (1969), “Design of Foam-Filled Structures,” Technomic Publishing Co., Stamford,
CT.
2. J.A. Hartsock and K.P. Chong, (1976), “Analysis of Sandwich Panels with Formed Faces,”
Journal of the Structural Division, ASCE, Volume 102, ST4, April; Article 12058; pp. 803-819.
3. J.C. LaBelle, (1990), “Structural Behavior of Aluminum/Elastomer Sandwich Beams”. A thesis

in partial fulfillment of the requirements for Doctor of Engineering at the University of Wisconsin-
Milwaukee.
4. K. Wolf and D.R. Sherman, (1991), “Application of a Finite Element for Sandwich Beams”.
Department of Civil Engineering and Mechanics, University of Wisconsin-Milwaukee.
5. J.C. LaBelle, (1992), “New Structural Design (Method) Developed for Poured and Debridged
Thermal Barrier Framing,” Glass Digest, Ashlee Publishing, New York, NY, V. 71, n. 8, August, pp.
92-95.
6. J.C. LaBelle, (1996), “Developments in Sandwich Beam Theory and Practice,” Materials for the
New Millennium (K.P. Chong, Ed.) ASCE, V. 2, pages 1017-1026.
7. J.C. LaBelle, unpublished work.
8. M. Davies, unpublished work.

1827 Walden Office Square, Suite 550
Schaumburg, IL 60173
PHONE (847) 303-5664 FAX (847) 303-5774
WEBSITE www.aamanet.org
EMAIL [email protected]

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A M E R I C A N A R C H I T E C T U R A L

2.0 Introduction ......................................................................1

3.0 Thermal Barrier Materials.....................................................3

4.0 Design Guidelines...............................................................4

5.0 Environmental Impact .......................................................20

7.0 Appendices ......................................................................29

8.0 Attachments ....................................................................56

AAMA. The Source of Performance Standards, Product Certification and

This voluntary specification was developed by representative members of AAMA

Revised Date: 10/2004 Released Date: 12/2004

AAMA TIR-A8-04 Page 1

2.2.1 History of Poured and Debridged

2.2.2 History of Mechanically Locking Thermal

AAMA TIR-A8-04 Page 2

4. Resistance to wind loading must be adequate to

AAMA TIR-A8-04 Page 3

Following are cavity design guidelines for TENSILE AREA

2. Design the temporary aluminum bridge for removal without

AAMA TIR-A8-04 Page 4

IRREGULAR CUT - USUALLY

AAMA TIR-A8-04 Page 5

CUTTING TOO DEEP BRIDGE NOT REMOVED

AAMA TIR-A8-04 Page 6

9. Position the thermal cavity where it will

AAMA TIR-A8-04 Page 7

LUG HEIGHT THROAT FILL

12. Test all design variations for structural integrity.

The design guidelines given above are not meant to be

AAMA TIR-A8-04 Page 8

AAMA TIR-A8-04 Page 9

AAMA TIR-A8-04 Page 10

The final stage of the crimping process is the correction

AAMA TIR-A8-04 Page 11

4.2.2 Mechanically Locked, Preformed Profiles

AAMA TIR-A8-04 Page 12

4.3.1.2 Mixing Ratio

4.3.1.3 Viscosity, Mixed

4.3.1.4 Gel Life

4.3.1.5 Debridging Time

4.3.1.6 Cure Time

4.3.2 Thermal Barrier Material Quality

1. Material should be level and filled to the top of the cavity.

3. Appearance of the liquid surface should be smooth and free of

4. Processing should be done in a manner such that the cavity is held

AAMA TIR-A8-04 Page 13

4.3.5.3 Handling During Packing and Shipping

AAMA TIR-A8-04 Page 14

AAMA TIR-A8-04 Page 15

AAMA TIR-A8-04 Page 16

AAMA TIR-A8-04 Page 17

5. After completion of the crimping process, the

While operating the crimping machine all the standard

4.5.4 Handling, Care, and Maintenance

4.5.4.1 Handling in the Plant

4.5.4.3 Handling During Shipping

FIGURE 18 – PICTURE OF ROLLING PROCESS

AAMA TIR-A8-04 Page 18

AAMA TIR-A8-04 Page 19

To determine if this phenomenon is occurring in a specific